Prediction of the Dynamic Characteristics of a Milling Machine Using the Integrated Model of Machine Frame and Spindle Unit
The machining performance is determined by the
frequency characteristics of the machine-tool structure and the
dynamics of the cutting process. Therefore, the prediction of dynamic
vibration behavior of spindle tool system is of great importance for the
design of a machine tool capable of high-precision and high-speed
machining. The aim of this study is to develop a finite element model
to predict the dynamic characteristics of milling machine tool and
hence evaluate the influence of the preload of the spindle bearings. To
this purpose, a three dimensional spindle bearing model of a high
speed engraving spindle tool was created. In this model, the rolling
interfaces with contact stiffness defined by Harris model were used to
simulate the spindle bearing components. Then a full finite element
model of a vertical milling machine was established by coupling the
spindle tool unit with the machine frame structure. Using this model,
the vibration mode that had a dominant influence on the dynamic
stiffness was determined. The results of the finite element simulations
reveal that spindle bearing with different preloads greatly affect the
dynamic behavior of the spindle tool unit and hence the dynamic
responses of the vertical column milling system. These results were
validated by performing vibration on the individual spindle tool unit
and the milling machine prototype, respectively. We conclude that
preload of the spindle bearings is an important component affecting
the dynamic characteristics and machining performance of the entire
vertical column structure of the milling machine.
[1] Yoshimi Ito, Modular design for machine tool, McGraw Hill Company,
2008.
[2] Y. Seo, D. P. Hong, I. Kim, T. Kim, D. Sheen, and G. B. Lee, Structure
modeling of machine tools and internet-based implementation,
Proceedings of the 2005 Winter Simulation Conference, December 2005,
Orlando, Florida, USA.
[3] J. Tlusty, M. Polacek, The stability of machine tools against self-excited
vibrations in machining, 1963, in: Proceedings of the ASME
International.
[4] J. Tlusty, Dynamics of high-speed milling, Trans. ASME, Journal of
Engineering for Industry 108 (2) (1986) 59-67.
[5] F. Koenisberger, J. Tlusty, Machine tool structuresÔÇöVol. I: stability
against chatter, Pergamon Press, Englewood Cliffs, NJ, 1967.
[6] S.A. Tobias, W. Fishwick, The chatter of lathe tools under orthogonal
cutting conditions, Trans. ASME, Journal of Engineering for Industry 80
(1958) 1079-1088.
[7] N. Akt├╝rk, M. Uneeb, M. R. Gohar, The effects of number of balls and
preload on vibrations associated with ball bearings, Trans. ASME,
Journal of Tribology 119 (4) (1997) 747-753.
[8] S. P. Harsha, K. Sandeep, R. E. Prakash, Effects of preload and number of
balls on nonlinear dynamic behaviors of ball bearing system,
International Journal of Nonlinear Science and Numerical Simulation
4(3) (2003 ) 265-278.
[9] Y. Cao, Y. Altintas, Modeling of spindle-bearing and machine tool
systems for virtual simulation of milling operations, International Journal
of Machine Tools and Manufacturing 47 (2007) 1342-1350.
[10] M. A. Alfares, A. A. Elsharkawy, Effects of axial preloading of angular
contact ball bearings on the dynamics of a grinding machine spindle
system, Journal of Materials Processing Technology 136(1-3) (2003)
48-59.
[11] N. Lynagh, H. Rahnejat, M. Ebrahimi, R. Aini, Bearing induced vibration
in precision high speed routing spindles, International Journal of Machine
Tools and Manufacture 40(4) (2000) 561-577.
[12] M.R. Movahhedy, P Mosaddegh, Prediction of chatter in high speed
milling including gyroscopic effects. International Journal of Machine
Tools and Manufacture, 46(9) (2006) 996-1001.
[13] C. W Lin, J. F. Tu, and J. Kamman, An integrated thermo mechanical
dynamic model to characterize motorized machine tool spindles during
very high speed rotation, International Journal of Machine Tools and
Manufacture, 43(2003)1035-1050.
[14] S. Y. Jiang, S. F. Zheng, A modeling approach for analysis and
improvement of spindle-drawbar bearing assembly dynamics.
International Journal of Machine Tools and Manufacture, 50(
2010)131-142.
[15] Y. Altintas and S. Park, Dynamic compensation of spindle-integrated
force sensors. CIRP Annals - Manufacturing Technology 53(1
(2004)305-308.
[16] Y. Altintas and Y. Cao, Virtual design and optimization of machine tool
spindles. CIRP Annals Manufacturing Technology, 54(1)(2005) 379-382.
[17] J. P. Hung, Load effect on the vibration characteristics of a stage with
rolling guides, Journal of Mechanical Science and Technology 23(1)
(2009) 92-102.
[18] C. Y. Lin, J. P. Hung, and T. L. Lou, Effect of preload of linear guides on
dynamic characteristics of a vertical column-spindle system,
International Journal of Machine Tools and Manufacture 5(8) (2010)
741-746.
[19] K. J. Johnson, Contact mechanics, Cambridge University Press (1985).
[20] T.A. Harris, in: Rolling Bearing Analysis, third ed., John Wiley and Sons,
New York, 1991.
[21] D. E. Brewe, B. J. Hamrock, Simplified solution for elliptical-contact
deformation between two elastic solid, Trans. ASME, Journal of
Lubrication Technology 99 (1997) 485-487.
[22] J. A. Greenwood, Analysis of elliptical Herztian contacts, Tribology
International 30 (1997) 235-237.
[23] J. P. Hung, Y.L. Lai, C. Y. Lin, and T. L. Lou, Modeling the machining
stability of vertical milling machine under the influence of the preloaded
linear guide, International Journal of Machine Tools and Manufacture.
51(9)(2011)731-739.
[24] Hiwin Technologies Company. Hiwin linear guideway technical
information. Taiwan: 2000. http://www.hiwin.com/online_cat
[25] Hiwin Technologies Company. Hiwin ballscrews technical information.
Taiwan:2000. http://www.hiwin.com/online_cat
[26] THK Technologies Company. THK Ball screw technical information:
ball screw peripheral. http://www.thk.com/online_cat.
[27] THK CO., LTD., Features of the LM Guide,
http://www.thk.com/online_cat.
[28] Y. Altintas, E. Budak, Analytical prediction of stability lobes in milling,
Annals of the CIRP 44 (1995) 357-362.
[29] E. Budak, Y. Altintas, Analytical prediction of chatter stability in
millingÔÇöPart I: general formulation; Trans. ASME, Journal of Dynamic
Systems, Measurement, and Control 120 (1998) 22-30.
[1] Yoshimi Ito, Modular design for machine tool, McGraw Hill Company,
2008.
[2] Y. Seo, D. P. Hong, I. Kim, T. Kim, D. Sheen, and G. B. Lee, Structure
modeling of machine tools and internet-based implementation,
Proceedings of the 2005 Winter Simulation Conference, December 2005,
Orlando, Florida, USA.
[3] J. Tlusty, M. Polacek, The stability of machine tools against self-excited
vibrations in machining, 1963, in: Proceedings of the ASME
International.
[4] J. Tlusty, Dynamics of high-speed milling, Trans. ASME, Journal of
Engineering for Industry 108 (2) (1986) 59-67.
[5] F. Koenisberger, J. Tlusty, Machine tool structuresÔÇöVol. I: stability
against chatter, Pergamon Press, Englewood Cliffs, NJ, 1967.
[6] S.A. Tobias, W. Fishwick, The chatter of lathe tools under orthogonal
cutting conditions, Trans. ASME, Journal of Engineering for Industry 80
(1958) 1079-1088.
[7] N. Akt├╝rk, M. Uneeb, M. R. Gohar, The effects of number of balls and
preload on vibrations associated with ball bearings, Trans. ASME,
Journal of Tribology 119 (4) (1997) 747-753.
[8] S. P. Harsha, K. Sandeep, R. E. Prakash, Effects of preload and number of
balls on nonlinear dynamic behaviors of ball bearing system,
International Journal of Nonlinear Science and Numerical Simulation
4(3) (2003 ) 265-278.
[9] Y. Cao, Y. Altintas, Modeling of spindle-bearing and machine tool
systems for virtual simulation of milling operations, International Journal
of Machine Tools and Manufacturing 47 (2007) 1342-1350.
[10] M. A. Alfares, A. A. Elsharkawy, Effects of axial preloading of angular
contact ball bearings on the dynamics of a grinding machine spindle
system, Journal of Materials Processing Technology 136(1-3) (2003)
48-59.
[11] N. Lynagh, H. Rahnejat, M. Ebrahimi, R. Aini, Bearing induced vibration
in precision high speed routing spindles, International Journal of Machine
Tools and Manufacture 40(4) (2000) 561-577.
[12] M.R. Movahhedy, P Mosaddegh, Prediction of chatter in high speed
milling including gyroscopic effects. International Journal of Machine
Tools and Manufacture, 46(9) (2006) 996-1001.
[13] C. W Lin, J. F. Tu, and J. Kamman, An integrated thermo mechanical
dynamic model to characterize motorized machine tool spindles during
very high speed rotation, International Journal of Machine Tools and
Manufacture, 43(2003)1035-1050.
[14] S. Y. Jiang, S. F. Zheng, A modeling approach for analysis and
improvement of spindle-drawbar bearing assembly dynamics.
International Journal of Machine Tools and Manufacture, 50(
2010)131-142.
[15] Y. Altintas and S. Park, Dynamic compensation of spindle-integrated
force sensors. CIRP Annals - Manufacturing Technology 53(1
(2004)305-308.
[16] Y. Altintas and Y. Cao, Virtual design and optimization of machine tool
spindles. CIRP Annals Manufacturing Technology, 54(1)(2005) 379-382.
[17] J. P. Hung, Load effect on the vibration characteristics of a stage with
rolling guides, Journal of Mechanical Science and Technology 23(1)
(2009) 92-102.
[18] C. Y. Lin, J. P. Hung, and T. L. Lou, Effect of preload of linear guides on
dynamic characteristics of a vertical column-spindle system,
International Journal of Machine Tools and Manufacture 5(8) (2010)
741-746.
[19] K. J. Johnson, Contact mechanics, Cambridge University Press (1985).
[20] T.A. Harris, in: Rolling Bearing Analysis, third ed., John Wiley and Sons,
New York, 1991.
[21] D. E. Brewe, B. J. Hamrock, Simplified solution for elliptical-contact
deformation between two elastic solid, Trans. ASME, Journal of
Lubrication Technology 99 (1997) 485-487.
[22] J. A. Greenwood, Analysis of elliptical Herztian contacts, Tribology
International 30 (1997) 235-237.
[23] J. P. Hung, Y.L. Lai, C. Y. Lin, and T. L. Lou, Modeling the machining
stability of vertical milling machine under the influence of the preloaded
linear guide, International Journal of Machine Tools and Manufacture.
51(9)(2011)731-739.
[24] Hiwin Technologies Company. Hiwin linear guideway technical
information. Taiwan: 2000. http://www.hiwin.com/online_cat
[25] Hiwin Technologies Company. Hiwin ballscrews technical information.
Taiwan:2000. http://www.hiwin.com/online_cat
[26] THK Technologies Company. THK Ball screw technical information:
ball screw peripheral. http://www.thk.com/online_cat.
[27] THK CO., LTD., Features of the LM Guide,
http://www.thk.com/online_cat.
[28] Y. Altintas, E. Budak, Analytical prediction of stability lobes in milling,
Annals of the CIRP 44 (1995) 357-362.
[29] E. Budak, Y. Altintas, Analytical prediction of chatter stability in
millingÔÇöPart I: general formulation; Trans. ASME, Journal of Dynamic
Systems, Measurement, and Control 120 (1998) 22-30.
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:59005", author = "Jui P. Hung and Yuan L. Lai and Tzuo L. Luo and Hsi H. Hsiao", title = "Prediction of the Dynamic Characteristics of a Milling Machine Using the Integrated Model of Machine Frame and Spindle Unit", abstract = "The machining performance is determined by the
frequency characteristics of the machine-tool structure and the
dynamics of the cutting process. Therefore, the prediction of dynamic
vibration behavior of spindle tool system is of great importance for the
design of a machine tool capable of high-precision and high-speed
machining. The aim of this study is to develop a finite element model
to predict the dynamic characteristics of milling machine tool and
hence evaluate the influence of the preload of the spindle bearings. To
this purpose, a three dimensional spindle bearing model of a high
speed engraving spindle tool was created. In this model, the rolling
interfaces with contact stiffness defined by Harris model were used to
simulate the spindle bearing components. Then a full finite element
model of a vertical milling machine was established by coupling the
spindle tool unit with the machine frame structure. Using this model,
the vibration mode that had a dominant influence on the dynamic
stiffness was determined. The results of the finite element simulations
reveal that spindle bearing with different preloads greatly affect the
dynamic behavior of the spindle tool unit and hence the dynamic
responses of the vertical column milling system. These results were
validated by performing vibration on the individual spindle tool unit
and the milling machine prototype, respectively. We conclude that
preload of the spindle bearings is an important component affecting
the dynamic characteristics and machining performance of the entire
vertical column structure of the milling machine.", keywords = "Dynamic compliance, Milling machine, Spindle
unit, Bearing preload.", volume = "6", number = "7", pages = "1289-7", }
