Main spindle

Motor
selection
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 Data:
1. Bearing :
 Front – 7018C,OD/ID:140/90mm, B: 24mm.
 Rear – 7016C, OD/ID:125/80mm, B: 22mm
2. Power Chuck-165WH:
 Weight-13.7Kgf, Moment of inertia -0.063 Kgm2.
3 .Pulleys :
 Spindle pulley. OD/ID:180/70mm, Weight-7.4 Kgf.
 Motor pulley , OD/ID:90/40mm, Weight-2 Kgf.
4. Reduction ratio 2:1.
5. Rotary Cylinder:
 Weight : 12 Kgf, Moment of inertia:0.019 Kgm2
6. Spindle Speed range 290-8000 rpm.
7. Machine specification:
 Job max. dia.160 mm, Length-350 mm, Weight-
59 Kg.
8. Motor used: 1PH8103;5.5kW,1500-5200rpm

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 load inertia
 Total load inertia(jL),kgm2:
Jc+Jb+Js1+Jp+JR
 Jc: Inertia of chuck.
 Jb: Inertia of all bearings
 Js1: spindle Inertia.
 Jp: Pulley inertia.
 Jr: Rotary cylinder inertia

1. Inertia of chuck(Jc):
 Refer Manufacturer’s catalogue.
 Jc: 0.063kgm2

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 load inertia

2. Bearing inertia (jb)=

 3*(Front bearing Inertia)+ 2* (Rear bearing Inertia)
 Front bearing Inertia(jbf)= m*[(D1/2)2+(D2/2)2)/2
 m=1.34kg:D1:140mm; D2:90mm
 jbf = (1.34)[(0.140/2)2 + (0.090/2)2]/2 = 4.73x10-3 kgm2.
 Rear bearing inertia(jbr): m*[(D1/2)2+(D2/2)2)/2
 m=0.966kg; D1:125mm; D2:80mm
 =(0.966)*[(0.125/2)2+(0.080/2)2]/2 = 2.69x10-3
 Total bearing inertia(jb): 3*(4.73x10-3)+2(2.69x10-3)
=19.6x10-3kgm2= 0.0196kgm2

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 spidle inertia
3. Spindle inertia(Js1): (Ws/g)*[(D1/2)2+(D2/2)2)/2
 Ws: 20kgf=200N.
 D1:80mm(average dia).
 D2: 30mm(bore through spindle).
 Js1= (200/9.81)*[(0.08/2)2+(0.030/2)2]/2
 =0.0045kgm2

4. Pulley inertia (Jp): (Wp/g)*[(D1/2)2+(D2/2)2)/2

 Wp: 7.4kgf=74N; D1:OD= 180mm;D2:ID= 70mm.
 Jp= (74/9.81)*[(0.180/2) 2+(0.070/2)]2/2 =0.035kgm2

5. Rotary cylinder inertia(Jr):

 Refer Manufacturer's catalogue.
 Jr= 0.019kgm2
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 inertia referred to Motor
 Total load Inertia(JL): Jc+Jb+Js1+Jp+JR
JL= 0.063+0.0196+0.0045+0.035+0.019=0.1411kgm2

 Load inertia referred to Motor axis(JLr): JL/i2.

 i: Reduction ratio= 2:1.
 JL= 0.1411kgm2
 (JLr)= 0.1411/22 = 0.0352kgm2

Total load inertia at Motor axis(J): Jlr + Jp2

Jp2: Inertia of Motor pulley,kgm2 :
= (Wp2/g)*[(D1/2)2+(D2/2)2)/2
 Wp2: 2kgf=20N; OD(D1)= 90mm;ID(D2)= 38mm.
 Jp2=(20/9.81)*[(0.090/2)2+(0.038/2)2]/2 = 0.0025kgm2
 J= 0.0352+0.0025=0.0371kgm2

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 load inertia

 Motor details: 1PH8103-1x F

 Motor power: 5.6kW,
 Speed: 1500-5200rpm
 Inertia:0.0172kgm2;
 Rated Torque: 35Nm;
 Static torque: 38Nm.
 Shaft dia:38mm

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 Servo Motor selection
 Inertia ratio(jt)= Load inertia/Motor inertia.
 Selected Motor inertia: 0.0172kgm2
 Jt= 0.0371/0.0172= 2.15
 If it is less than 5 it is OK.

 Acceleration speed(na): 1500rpm.

 Static/Acceleration Torque of motor(ta): 38Nm
 Angular acceleration(a):Ta/J=38/0.0371=1024rad/sec2
 Acceleration time(ta): 2pn/60*a
 =2p*1500/(60*1024) =0.153sec=153msec.

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 feed Motor
evaluation

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 feed axis configuration
Lathe machine Z-axis : Horizontal axis.
Table(X-axis and turret) weight (Wt):
2400N
Cutting fiorce(Fc): 5000N
Ball screw dia(d)/lead(l):32/12mm
Stroke: 350mm.
Ball screw length: 750mm
Ball screw length(L): 1400mm
Max. linear speed(v):
24000mm/min(24m/min)
Friction of sliding surfaces(m): 0.01
Acceleration/deceleration time(ta/td) =
100ms=0.100s
Direct drive (no reduction).
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 load and operating speed
 Slide Movement is Horizontal.  Cutting power(P),kW: 5kW.
 Total slide load(Wt)=  Cutting speed(v),m/min: 150.
 m*W= 0.01*2400=24N.  Tangential force(Ft),N: P/v
 Max. linear speed(v) : 24m/min.  Ft=5*1000*60/150 = 2000N
 Ball screw rotational speed(nmax): (v/l)  Ff= say 0.7Ft=0.7*2000=1400N
nMax= 24000/12=2000 rpm.  Axial force acting on spindle.
 Cutting feed force=Axial force acting  FP= say 0.5Ft=0.5*2000=1000N
on ball screw.  Radial force acts in Horizontal
 Feed force(Ff)= 1400N plane.

Total axial load (Fa): Ff+Wt= 1400+24=1424N.

Preload(Fv): Fmax/3= 1424/3=475N
Ball screw efficiency:0.9(Assumed)

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 drive torque
 Drive Torque during Machining(Tc):  Torque referred to Motor axis(TCr)
 For pre loaded screw: [(0.9Tp)+Td+Tb+Tf).  Tcr: Tc*(n2/n1)
 For Non preloaded screw: (Tp+Tb+Tf).  n1/n2: Speed reduction
 Tp: Torque due to external load.  n1:Motor speed, rpm
 Tp=Fa*l/2ph=1424*12/2p*0.9= 3023Nmm.  n2: Feed screw speed, rpm
 Td: Torque due to Preload.  Direct drive:
 Td= Fv*l/2p = 475*12/2p =908Nmm  So n1/n2=1 for our application
 Tb: Friction torque of bearings  Tcr = Tc =3788Nmm.
Tb= Fa*mb*d/2 =1424*0.002*(25/2)= 36Nmm
 For four bearings(Tb):4*36=144Nmm
d: Bore dia of bearing,mm
 Tf :Friction torue of Oil seals,couplings etc. Selected motor torque(Tm) should be
Tf=10Nmm (Assumed) 10 to 30% more than Drive torque(Tc)
 Total Load/Drive Torque(Tc):
 Preloaded screw and Direct drive.
 Tc= (0.9Tp+Td+Tf)
 Tc=[0.9*3023+908+144+10]=3788Nmm=3.8Nm

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 Acceleration torque
 Acceleration torque(Ta): Jt*a, Nm
 Jt: Inertia referred to motor axis,kgm2
a: Angular acceleration, rad/sec2= 2pn/60*ta
 n=Acceleration speed, rpm
 ta= Acceleration time, sec.
 Jt: [Jl/(n1/n2)2]+(Jg2+Jm)
 Jl : Mass Moment of inertia of feed system,kgm2
Jl= Ji+Jbs+Jg1
Ji: Load inertia,kgm2
Jbs: Ball screw inertia, kgm2 n1/n2= Motor speed/Feed screw speed
Jg1: Inertia of Gear/Pulley on Feed screw, kgm2
( For reduction drives)
Jg2: Inertia of Gear/Pulley on Motor axis, kgm2 (
For reduction drives)
Jm: Motor inertia,kgm2.
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 inertia calculations
Ji: Load inertia=(W/g)*(l/2p)2  Jg1,2: Gear/ pulley inertia,kgm2
W: Total static load, 2400N Jg1,2= (mg1,2)*(d22+d12)/8
 d1: Bore of gear/pulley,m
l: Pitch of ball screw,12 mm=0.012m  d2: OD of gear/pulley,m
Ji= (2400/9.81)*(0.012/2p)2 =0.0009 kgm2 mg1,2 = Mass of gears,kg
 Motor is directly coupled to ball screw
Jbs= Ball screw inertia=[pr Hence Jg1=Jg2=0
Ld4/32*g](n1/n2)2
r: Density of steel: 78500N/m3
 Jm: Motor inertia.
L=Length of ballscrew,750mm=0.75m  to be selected from Motor catalogue.
d: dia of ball screw,32mm=0.032m
Jbs=[p*78500*0.75*(0.032)4/(32*9.81)}
=0.0006kgm2

Jl= 0.0009+0.0006=0.0015kgm2

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 inertia and acceleration torque
Selected Motor 1FK7063-XXX-
Tm= 7.3Nm;Jm=0.0015kgm2; nm=3000rpm
High short-term overload capacity (250ms)
Tmax= 3*Tm(100 K).
 Jm=0.0015kgm2; Jl=0.0015kgm2
 Jl/Jm=0.0015/0.0015=1
 So selected Motor inertia is Good
 Total inertia(Jt)=Jm+Jl
 Jt=0.0015+0.0015=0.0030kgm2

Motor torque (Tm): 7.3Nm;

Load/continuous torque(Tc): 3.8Nm
Tm/Tc=7.3/3.8= 1.9.
So selected Motor is safe.
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 Servo Motor selection
 Angular acceleration(a):
 Acceleration speed(na): 2000rpm.
 Acceleration Time,sec(ta): 0.100sec.
 a=2pn/60*ta=2p*2000/(60*0.100) = 2094rad/sec2.
 Acceleration torque(Ta)=ja = 0.0030*2094
=6.28Nm=6280Nmm.
 Drive torque required to move Dead load(Td) =Fad*l/2ph
 = 0.01(2400)*12/(2p*0.9)= 51Nmm
 Max.torque(Tmax): Ta+Td = 6280+51=6331Nmm=6.33Nm.
 Continuous torque(Tc)= 3.8Nm
Power(P)= nT/9550=1000*3.8/9550
=0.39kW =390W

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 Servo Motor selection

Selected Motor
Siemens Feed Motor : 1FK7063-XXXX-
(Page2/4).
Rated Torque(Mr): 7.3Nm;
Accelration torque(Mo): 11Nm
Inertia(Jm): 0.0015kgm2;
Nax.Speed(nmax.):3000rpm;
Motor Power(Pm): 2.3kW

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 thanks

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