工具機專題

主軸多重物理分析
Multiphysics analysis of spindles
陳任之
最新版 (包括課後更新)
投影片在此
2022.03
Reference materials in English
E. Abele, Y. Altintas, C. Brecher
Machine tool spindle units
CIRP Annals, 59:2 (2010) 781–802
Bernd Bossmanns, Jay F. Tu
A thermal model for high speed motorized spindles
International Journal of Machine Tools & Manufacture
39 (1999) 1345–1366
 複習：主軸形式 Revision: types of spindles
驅動方式
(Types of drives)
 直結式 (Direct-drive)
 內藏式 (Motorised spindle)
 皮帶式 (Belt-driven)
軸承預壓方式
(Preloading method) Thickness difference < 10 um)
 定位預壓 (Position/offset preload)
 定壓預壓
(Constant pressure/spring preload)
 優缺點?
1. 剛性 stiffness
2. 溫度上升的影響
effect of temperature

NSK Machine tool spindle: bearing selection and Mounting Guide (2009)
Quantifying rotating speed
𝑑𝑜 +𝑑𝑖
DmN = 𝑛
2
where
 𝑛 = Maximum Operating Speed (rpm)
 𝑑𝑜 = Bearing Outside Diameter (mm)
 𝑑𝑖 = Bearing Inside Diameter (mm)

Example:
 Bearing type 7020 running at 7,000 rpm
Size: 𝑛𝑖 =100mm, 𝑛𝑜 =150mm
DmN = 7,000 rpm x (150mm + 100mm)/2
= 875,000
Outline

耗電分析 Power consumption

靜剛性分析 Static stiffness analysis
動剛性分析 Dynamic stiffness analysis
轉子動力學分析 Rotordynamics
最佳預壓量分析 Optimal preload level
顫振分析 Chatter
熱分析/多重物理耦合 Thermal/multiphysics
 複習：航太加工的需求?
主軸馬達與驅動器 Revision: Requirements of aerospace
parts machining?

工具機需於不同轉速及扭矩
下加工
 例：航太加工需要的轉速和扭矩?
達成方式：可變頻式驅動
(Variable frequency drive, VFD)

三相電，60 Hz 三相電
頻率可變
市電 3-phase power w/
variable frequency
三相電箱
馬達電工學分析
主軸功率 = 扭矩*轉速
三相電
 三角/Y 型接線
 Wye start Delta run

http://acim.nidec.com/motors/usmotors/techdocs/profacts/starting-methods/wyestart-deltarun
https://qph.fs.quoracdn.net/main-qimg-411148103b50a3a57823168d15817b50-c
交流馬達的極數 (poles in AC motor)
極數 (pole) N = 定子的磁極對數*2
 三相馬達中，同一相才計算在內
與內部繞線有關 2-pole motor

6-pole motor

https://i.stack.imgur.com/Ww3Nq.gif
http://www.industrial-electronics.com/images/emcs_5-31.jpg
 常用交流馬達種類 Common AC motor types
感應異步馬達 Induction asynchronous motors
又稱鼠籠馬達 (Squirrel cage motors)
永磁同步馬達 Permanent magnet synchronous motors
同步 Synchronous =轉速 𝑛 與電頻率 𝑓 有關
2 60𝑓
𝑛 (rpm) =
𝑁
馬達損耗 (Losses in motors)
 銅損 (Copper loss)：與電流有關之能耗
 鐵損 (Iron loss)：與磁場有關之能耗

下課後加入的材料

https://pnpntransistor.com/wp-content/uploads/2018/10/squirrel-cage-induction-motor-rotor.jpg
https://i.pinimg.com/originals/82/19/2c/82192c34252e3d63e5d8c8fa4778c65c.jpg
 https://impremedia.net/torque-slip-characteristics-of-induction-motor/#

感應馬達特性
Properties of induction motors
無負載時，轉速 𝑛 與電流頻率 𝑓 同步
Rotation speed 𝑛 is synchronous with electric
frequency 𝑓 when idle (馬達電源頻率固定時之力矩—轉速曲線)
有負載時 under loading
2 60𝑓
𝑛<
𝑁
 差異 = 滑移 (difference = slip)
 馬達輸出扭矩，與滑移有關
Output torque is a function of slip
2 60𝑓
編碼器量測實時轉速(和位置) 𝑛=
𝑁
Real-time speed (and position)
measured using encoder 馬達出力範圍

不同曲線= 不同電流頻率
 永磁同步馬達 Permanent magnet
synchronous motor (PMSM)
轉子為稀土類材料永久磁石
優點
1. 沒有激磁場的銅損
2. 體積較低，提高效率與功率密度
3. 扭力較高
缺點
1. 稀土類材料較昂貴
2. 控制器須重新設計
3. 安裝困難
4. 頓轉轉矩
定子線圈
(Stator coils) 轉子永磁鐵
https://asia.toshiba.com/permanent-magnet-synchronous-motor/ (Rotor Permanent
magnets)
 頓轉轉矩 Cogging torque/torque ripple
永磁馬達轉動時轉矩起伏 Stator

頓轉轉矩頻率（ a =槽數
與極數的最小公倍數）
𝑛
𝑓𝑐 = 𝑎
60 頓轉轉矩總和=0
馬達產生噪音和震動 Rotor
magnet

降低頓轉轉矩的方法： Stator
1. 改變轉子磁石剩磁強度
2. 改變轉子及定子排列方式
及尺寸
3. 槽極與磁極不同的組合
Reference ：郭景全，降低永磁無刷馬達頓轉轉矩之研究，
逢甲大學碩士論文，2006年
Rotor 頓轉轉矩總和≠0
magnet
Duty cycles S1 and S6
加工負載常被假定為 S1 或 S6 負載，並
據此計算馬達最高輸出功率
Machining load is typically assumed as duty
cycle S1 or S6, and motor capability is then
estimated

https://mall.industry.siemens.com/mall/en/WW/Catalog/Products/10234353
馬達負載周期表示 Motor duty cycle (EN 60034-1)
Term Description
The motor works at a constant load for enough time to reach
S1 Continuous duty temperature equilibrium.
The motor works at a constant load, but not long enough to reach
S2 Short-time duty temperature equilibrium. The rest periods are long enough for the motor
to reach ambient temperature.
Sequential, identical run and rest cycles with constant load. Temperature
Intermittent periodic
S3 equilibrium is never reached. Starting current has little effect on
duty temperature rise.
Sequential, identical start, run and rest cycles with constant load.
Intermittent periodic
S4 Temperature equilibrium is not reached, but starting current affects
duty with starting temperature rise.
Intermittent periodic Sequential, identical cycles of starting, running at constant load and
S5 running with no load. No rest periods.
duty with electric braking
Continuous operation Sequential, identical cycles of running with constant load and running
S6 with no load. No rest periods.
with intermittent load

S7-S10 Duty cycle ratings are sometimes used as well.

Reference: K.C. Agrawal (2007): Electrical Power Engineering: Reference & Applications Handbook,
CRC Press
Outline

耗電分析 Power consumption

靜剛性分析 Static stiffness analysis
動剛性分析 Dynamic stiffness analysis
轉子動力學分析 Rotordynamics
最佳預壓量分析 Optimal preload level
顫振分析 Chatter
熱分析/多重物理耦合 Thermal/multiphysics
 Spindle rotor as a beam 理論的誤差?

Static stiffness k = ratio of P to

𝛿 𝛿
𝑃𝑎2 3𝐸𝐼
𝛿= (𝑎 + 𝐿), 𝑘 =
3𝐸𝐼 𝑎2 𝑎+𝐿
Improved model with bearings
with lateral stiffness
2
1 𝑎+𝐿 1 𝑎 2 𝑎2 𝐿 𝑎
𝛿=𝑃 + + +
𝑘𝑅 𝐿 𝑘𝐿 𝐿 3𝐸 𝐼𝐿 𝐼𝑎
𝛿1 𝛿2

2
1 1 𝑎+𝐿 1 𝑎 2 𝑎2 𝐿 𝑎
= + + +
𝑘 𝑘𝑅 𝐿 𝑘𝐿 𝐿 3𝐸 𝐼𝐿 𝐼𝑎
http://pressurevesseltech.asmedigitalcollection.asme.org/data/journals
/jmsefk/27501/020101j.1.jpeg

心軸最小跨距 = 馬達長度
Bearing stiffness
Bearing stiffness depends on preload level
Preload L M H
Rigidity 170.1 N/μm 274.3 N/μm 373.5 N/μm
Source: FAG catalogue (B7014-E-T-P4S)

Preload may change in spindles with offset preload!

軸向與徑向剛性比例與接觸角有關
Angle K_r / K_a
15° 6
20° 3.5
25° 2

(Please consult catalogs)

Source: FAG catalogue

 Equilibrium of bearing balls
Bearing balls lean outward due to centrifugal force
 Contact angles changed

接觸角 𝛼

靜止 運轉時

Source: FAG technical presentation

Change of bearing stiffness upon rotation
Overall stiffness
Bearing stiffness model 1 1
−1
𝑘= +
𝑘𝑖 𝑘𝑜

ki ko
𝑘𝑜 decreases when
contact angle increases
 If 𝑘𝑖 ≪ 𝑘𝑜 , 𝑘 ≈ 𝑘𝑖
 General reduction of
bearing stiffness

Right below: Rantatalo (2006)

軸承剛性量測
Bearing stiffness measurement
Physical principle
𝐹 = 𝑘𝑥
Easy, if spindle does not rotate

Experiment on rotating spindles has to be non-

contact
What types of non-contact excitation available?
 Electrostatic
 Pneumatic
 Electromagnetic excitation (Problem: 𝐹 ∝ 𝑖 2 )
Rantatalo (2006)
Stiffness of bearing under rotation
MEASUREMENT OF MEASUREMENT OF
EXCITATION RESPONSE
Force gauge Laser/Hall effect/
capacitive displacement sensor
Laser Doppler
Velocimeter (LDV)
Outline

耗電分析 Power consumption

靜剛性分析 Static stiffness analysis
動剛性分析 Dynamic stiffness analysis
轉子動力學分析 Rotordynamics
最佳預壓量分析 Optimal preload level
顫振分析 Chatter
熱分析/多重物理耦合 Thermal/multiphysics
 Types of excitation Cutting force
(Broadband)
on spindle
Bearing
Damage

Unbalance

Misalignment
http://images.books24x7.com/bookimages/id_9018/fig118_01.jpg
http://i.imgur.com/LJp1r.jpg
Brief revision to simple harmonic motion
Basic components in dynamic system
 質塊 𝑚 ，儲存動能 Block mass 𝑚 to store kinetic energy
 彈簧(剛性為𝑘) ，儲存應變能Spring with stiffness 𝑘
 黏滯阻尼器 (係數為𝑐) Damper with coefficient 𝑐
From Newton’s second law of motion,
𝑚𝑥ሷ 𝑡 + 𝑐 𝑥ሶ 𝑡 + 𝑘𝑥 𝑡 = 𝑓 𝑡

簡諧外力下 (𝑓 𝑡 = 𝐹 sin 𝜔𝑡),

Under harmonic excitation, 1.5

𝒇(𝒕)
 響應也是簡諧 Response is harmonic 1

 兩者頻率相同 Both have same frequency0.5

𝒙(𝒕)
 但響應幅度和相位差則視頻率而定… 0
(Response amplitude and phase shift 0 50 100 150 200
are unknown) -0.5

𝝓-1
-1.5
自然頻率 Natural frequency
𝑚𝑥(𝑡)
ሷ + 𝑐 𝑥(𝑡)
ሶ + 𝑘𝑥(𝑡) = 𝑓(𝑡)
假設簡諧運動:
𝑥 𝑡 = 𝐴 sin 2𝜋𝑓𝑡 𝑥ሷ 𝑡 = −𝐴(2𝜋𝑓)2 sin 2𝜋𝑓𝑡
假設無阻尼、無外力而振幅非零:
(assume no damping, no excitation but with finite response)
𝑘 − 𝑚(2𝜋𝑓)2 𝐴 sin 2𝜋𝑓𝑡 = 0
若無外力，A 可以不等於0

𝑓𝑛 =
1 𝑘 自然頻率
2𝜋 𝑚 (與振幅無關!)
𝑘
(𝜔𝑛 = 2𝜋𝑓𝑛 = )
𝑚
 Dynamic stiffness
動剛性 Source: Altintas and Cao (2005)

Theoretical definition
𝐹 𝜔
 k = F/x -> 𝑘𝑑 =
𝑥 𝜔
where 𝜔 = 2𝜋𝑓
Practical definition
 Frequency response 0.05

function (FRF) 一般觀察到的共振

Dynamic stiffness is a Observable resonance
COMPLEX quantity
Dynamic stiffness has imaginary
part if F and x are not in phase!
Simplified model of spindle
Key components must be included in the same model
What are the error sources involved in
the finite element model?
樑元素 (beam elements)
Measure dynamic stiffness - Experimental modal
analysis
Definition:
𝐹 𝜔
𝑘𝑑 =
𝑥 𝜔
Equipment
 Most common: hammer +
accelerometers
 Impact hammer
 Accelerometer
 Hall effect sensor (渦電流位移
計)
 Capacitive displacement sensor
 Laser Doppler vibrometer
Curve-fitting used to find
natural frequencies

(Peeters et al. (2004))

Vibration testing vs Experimental modal analysis
(實驗模態分析) (or Modal testing 模態測試)
VIBRATION TESTING EXPERIMENTAL MODAL ANALYSIS
MEASURE VIBRATION LEVEL UNDER OBTAIN FRFS TO FIND NATURAL
SEVERAL RUNNING PARAMETERS
FREQUENCIES AND MODE SHAPES

最好知道激振的點、方向和量
Case study: modal analysis of shaft
模型簡化 樑的自然頻率
 低頻分析視心軸為剛體，軸承為彈簧 𝜔∝
1 𝐸𝐼
 高頻分析視心軸為樑 𝐿2 𝜌𝐴

設計目標 Design objective

 第一自然頻率𝜔1 > 最高轉速 First natural frequency > rated
rotation speed
 例: 24000 rpm -> 𝜔1 > 400 Hz
內藏式主軸中不易做到 Not readily achievable in
motorized spindles
 跨距較長 Longer Span (Why?)
 馬達轉子質量 Mass of motor rotor
 Experimental
3 Spindles Comparison (axis Y) of Mode 1
1
Spindle 01 F=953.9124Hz
0.8 Spindle 02 F=950.6676Hz
Spindle 03 F=950.6835Hz
0.6

modal analysis 0.4

0.2

Y (mm)
0

每一自然頻率對一個模態 -0.2

-0.4

-0.6

Example: tests on 3 shafts of -0.8

0 50 100 150 200 250 300 350
3 Spindles Comparison (axis Y) of Mode 2
400 450 500

same type 1.5 X (mm)

Spindle 01 F=2519.593Hz
Spindle 02 F=2512.417Hz

 Natural frequencies and mode shapes

1 Spindle 03 F=2512.32Hz

0.5

match

Y (mm)
(Variation of 𝜔𝑛 ≤0.5%) 0

 Reason of uneven distribution of 𝜔𝑛 ?

-0.5

-1

-1.5
0 50 100 150 200 250 300 350 400 450 500
Natural freq. (axial hit) (Hz)

3 Spindles Comparison (axis Y) of Mode 3

2 X (mm)

1.5

0.5
Y (mm)

-0.5

-1
Spindle 01 F=4832.581Hz
-1.5 Spindle 02 F=4821.408Hz
Spindle 03 F=4822.943Hz

-2
0 50 100 150 200 250 300 350 400 450 500
X (mm)
Natural frequency (Lateral hit) (Hz)
Measurement of
rotating spindles
Effect of drawbar force
Rotor Natural frequency increases with drawbar force

Compression
Tension
Compression
Outline

耗電分析 Power consumption

靜剛性分析 Static stiffness analysis
動剛性分析 Dynamic stiffness analysis
轉子動力學分析 Rotordynamics
最佳預壓量分析 Optimal preload level
顫振分析 Chatter
熱分析/多重物理耦合 Thermal/multiphysics
 課堂上未詳細討論

Bearing-related vibration frequencies

Frequency (Hz)

Ball-pass frequency (inner) BPFI 𝑁𝑛 𝑑𝑏

1 + cos 𝜙
120 𝑑𝑝
Ball-pass frequency (outer) BPFO 𝑁𝑛 𝑑𝑏
1 − cos 𝜙
120 𝑑𝑝
Fundamental train frequency FTF 𝑛 𝑑𝑏
1 − cos 𝜙
120 𝑑𝑝
Ball spin frequency BSF 2
𝑑𝑝 𝑛 𝑑𝑏
1−
120𝑑𝑏 𝑑𝑝 cos 𝜙

𝜙=contact angle
𝑛= rotation speed in rpm Bearing balls experience Hertz stress when rolling
𝑁=number of balls
𝑑𝑏 = ball diameter
𝑑𝑝 = pitch diameter
𝜙= contact angle
http://www.ntnamericas.com/en/website/d
ocuments/brochures-and-literature/tech-
sheets-and-supplements/frequencies.pdf
Rotor Unbalance
Vibration frequency
= rotation speed
Grades Gxx as defined in
ISO 21940
Removing unbalance
 Two-plane balancing
 Holes are pre-drilled in spindle rotor
for balancing

http://www.irdbalancing.com/downloads/techpaper1balqualityreqmts.pdf
The need of two-plane balancing

𝐹 = 𝑚𝑟𝜔2

Centrifugal forces result

in couple
Centrifugal
forces balanced

Macdara MacCamhaoil, “Static and Dynamic Balancing of Rigid Rotors”, B&K Technical Note (1989)
Two-plane balancing procedure
Principle: by trial-and-error with KNOWN masses at
KNOWN angles

Static and Dynamic Balancing using portable

measuring equipment by John Vaughan
 Waterfall diagram
A graph filled with FOURIER
domain quantities
Measure vibration of
accelerating spindle
Y axis – frequency 12 N
 natural frequencies 𝜔𝑛
X axis – rotation speed
 (Slanted lines = 𝑛𝛺)
Color – Vibration level
Resonance occurs when
𝑛𝛺 = 𝜔𝑛 3𝛺
2𝛺
Vibration level ≠ dynamic stiffness 𝛺
as the excitation 𝐹 𝜔 is unknown

Accelerating spindle
Campbell diagram
CAMPBELL DIAGRAM WATERFALL DIAGRAM
分析的結果 實驗資料
 檢查發生共振的馬達轉速  理想中與 Campbell 圖重疊
兩種線：如兩種線交叉，即會  兩種線交叉處的振動量為最高
產生共振
 自然頻率線 (橫線)
 馬達轉速倍頻線 (斜線)
轉子動力學分析 Rotordynamics analysis

Rotordynamics: Application of vibration theory to rotors

Swanson et al., (2005)

Whirling 晃動

Vibrations in rotating shafts usually exhibited as whirling

 Due to gyroscopic forces
 Forward whirling is more common
 Backward whirling occurs when bearing stiffness on x and y
directions are different
Waterfall diagram revisited

Mode splitting means forward and

backward whirling have different
natural frequencies. This is
prominent in modes with mass
rotating w.r.t. x or y axis
Outline

耗電分析 Power consumption

靜剛性分析 Static stiffness analysis
動剛性分析 Dynamic stiffness analysis
轉子動力學分析 Rotordynamics
最佳預壓量分析 Optimal preload level
顫振分析 Chatter
熱分析/多重物理耦合 Thermal/multiphysics
Increased bearing preload

Two effects in offset-preload

bearings
Radial expansion Axial lengthening
 Radial expansion
 Axial lengthening
Compensation
 Use spring/constant pressure
preload

Source: Lin, Tu and Kamman (2003)

 𝑛 Spin-to-Roll ratio
B
tanε =
Preload Preload + Force equilibrium
R
Centrifugal Force
aA
Risk of skidding
High Speeds if spin-to-roll ratio > 0.5
Outer Raceway Control wR
wB

wJ
wR
aI e

wR
e
wA

wB Methods:
Inner Raceway Control wR
1. Catalogue-based calculation
Low Speeds 2. Calculation software from
Source: FAG technical presentation
bearing manufacturers
Relationship between preload and rotation speed
軸承預壓影響
 材料力學：主軸靜動剛性、自然頻率
 動力學：打滑機率
 熱產生

Rotation speed

Preload
Preload analysis

Receptance
PRELOAD = 92 N

Receptance

PRELOAD = 115 N

Source: Gunduz et al., 2012 Frequency (Hz)

Outline

耗電分析 Power consumption

靜剛性分析 Static stiffness analysis
動剛性分析 Dynamic stiffness analysis
轉子動力學分析 Rotordynamics
最佳預壓量分析 Optimal preload level
顫振分析 Chatter
熱分析/多重物理耦合 Thermal/multiphysics
We need high productivity. But…
Forced vibration
Cutting instability -> Chatter
 Cutting “too quick” or “too deep”
 Related to dynamic stiffness
 Poor surface finish Altintas & Weck (2004)

Excessive vibration level at bearings

(or workpiece), bearing life shortened

Axial cutting depth

Spindle speed
Source: Quintana, G. & Ciurana, J. (2011)
Stability lobe diagram
Indicate region of stability

Different lines indicate

number of periods
2𝜋𝑓𝑐 𝑇 = 2𝑘𝜋 + 𝜖
 𝑓𝑐 = chosen chatter
vibration frequency
 𝑇 = Period of rotation
Stability boundary
Stability boundary

Shanshin et al. (2019)

Chatter and structural dynamics
Instability Structural dynamics
of machine
 Ever-increasing amplitude (video)
Cutting
Chatter is related to force
 Cutting mechanics (relationship Cutting
between cutting depth and force) mechanics Vibration
 Structural dynamics (relationship
between excitation force and response)
External forces is a type of “negative damping”

單自由度系統：
𝑚𝑥(𝑡)
ሷ + 𝑐 𝑥(𝑡)
ሶ + 𝑘𝑥(𝑡) = 𝑓(𝑡)

Altintas book
Determining stability boundary 𝑥(𝑡 − 𝜏)

𝑥(𝑡)

Simplified expression of cutting force 𝑥(𝑡)

𝑥(𝑡 − 𝜏)
𝑓(𝑡) = 𝐾𝑓 𝑎ℎ
= 𝐾𝑓 𝑎 ℎ0 − 𝑥 𝑡 + 𝑥 𝑡 − 𝜏

If oscillation 𝑥 𝑡 = 𝑋𝑒 𝑗 𝜔𝑡−𝜙
,
𝑥 𝑡 − 𝜏 = 𝑋𝑒 −𝑗𝜔𝜏 𝑒 𝑗 𝜔𝑡−𝜙

𝐹 𝜔 = −𝐾𝑓 𝑎 1 − 𝑒 𝑗𝜔𝜏 𝑋(𝜔)

Determining stability boundary

For the cutting tool,

𝑚𝑥ሷ 𝑡 + 𝑐 𝑥ሶ 𝑡 + 𝑘𝑥 𝑡 = 𝑓 𝑡 k

Assuming sinusoidal motion,

c a
𝑋 𝜔 1
Φ 𝜔 = = = 𝐺𝑅 + 𝑗𝐺𝐼
𝐹 𝜔 𝑘 + 𝑗𝑐𝜔 − 𝑚𝜔 2
𝐺𝐼
𝐺𝑅
If 𝑓 𝑡 is cosine

 𝐺𝑅 refers to cosine motion

 𝐺𝐼 refers to sine motion

𝐺𝑅 at maximum,
Leading to smallest 𝑏
Determining stability boundary
𝑓(𝑡) = 𝐾𝑓 𝑎 ℎ0 − 𝑥 𝑡 + 𝑥 𝑡 − 𝜏
For cutting tool, 𝑥(𝑡 − 𝜏)
𝑚𝑥ሷ 𝑡 + 𝑐 𝑥ሶ 𝑡 + 𝑘𝑥 𝑡 = 𝑓 𝑡 𝑥(𝑡)

Assuming sinusoidal motion,

𝑋 𝜔 1
Φ 𝜔 = = 2
= 𝐺𝑅 + 𝑗𝐺𝐼
𝐹 𝜔 𝑘 + 𝑗𝑐𝜔 − 𝑚𝜔
Dynamic cutting force 𝐹(𝜔) = −𝐾𝑓 𝑎 1 − 𝑒 𝑗𝜔𝜏 𝑋(𝜔)
Rearranging the terms, 𝐺𝐼
𝑋 𝜔 = ℎ0 − 𝐾𝑓 𝑎 1 − 𝑒 𝑗𝜔𝜏 𝑋 𝜔 𝐺𝑅

𝑋 𝜔 1
=
ℎ0 1 + 𝐾𝑓 𝑎 1 − 𝑒 𝑗𝜔𝜏
Chatter -> unstable transfer function
𝐺𝑅 at negative maximum,
Leading to smallest ℎ0
 課堂上未詳細討論

Drawing stability lobe diagram

4 Steps
1. Select a chatter frequency at the negative real part of the
transfer function
2. Calculate the phase angle of the structure
sin 𝜔𝑐 𝑇
tan 𝜓 =
cos 𝜔𝑐 𝑇 − 1
3. Calculate the critical depth of cut
1
ℎ0 = −
2𝑅𝐺𝑅 𝜔𝑐
4. Calculate the spindle speed for each stability lobe 𝑘 =
0, 1, 2 …
1 Stability boundary

2
Outline

耗電分析 Power consumption

靜剛性分析 Static stiffness analysis
動剛性分析 Dynamic stiffness analysis
轉子動力學分析 Rotordynamics
最佳預壓量分析 Optimal preload level
顫振分析 Chatter
熱分析/多重物理耦合 Thermal/multiphysics
Spindle thermal analysis: Motivation
Consequences
 Bearing lubricant life
 Thermal deformation
 Increased bearing preload
Preload level Natural
frequencies

Contact angle, etc. Elongation

MATLAB

BearinX Bearing Stiffness

Rotation speed Temperature B.C. ANSYS Heat distribution

BearinX
Heat conduction
Experiments coefficient
Bearing Life
Coolant flow rate
Heat development in motorized spindles
30 30
high-frequency spindle unit

40 41 40 40
45
40
40 130 70 130
45
45 160 80 60
50 70 90

50 70 110 150 150 110 70 50

90 130 130 90

High temperature Low temperature

◼ Shaft ◼ Housing
◼ Inner ring of bearing ◼ Outer ring of bearing
◼ Ball set
◼ Cutting load (minor)
實驗量測
Temperature measurement of spindles
IR temperature sensor
紅外線熱像儀

PT100 (電阻型)

Thermocouple
熱電偶

https://www.pixsys.net/uploads/big_Temperature_sensor__pt100_Easy_up_6mm_Air_probes.jpg
https://qph.fs.quoracdn.net/main-qimg-931d7a864a2abffab2745c2753331b37
. http://chemicalplantsafety.net/wp-content/uploads/2010/09/infrared-temperature-measurement.jpg
Thermal analysis of spindles
Fluid-structure interaction (FSI)
problem
• 1-Way problem: transferring thermal
data for structural analysis (e.g.
thermal deformation)
• 2-Way problem
Stronger cooling not always better!

Analysis with Simplified model

 Finite difference method
 Heat conduction
𝜕𝑇
𝑄 = 𝑘𝐴
𝜕𝑥
 Heat convection
Source: Bossmann and Tu (1999)
熱變形 Thermal deformation
Three types
 Radial expansion
 Axial lengthening
 Bending due to uneven
temperature distribution
Deformation in axial directions
can be compensated easily, but
not for bending
軸承產生熱量 Heat generated in bearings
軸承產生熱量
𝑛
𝑊 =𝛤⋅𝜔 =𝛤⋅
9.55
其中 Γ 為摩擦力矩 (friction torque)
假設 Γ = Γ𝑙 + Γ𝑣 ，Γ𝑙 與負載（loading, 徑向力）有關，Γ𝑣 與轉速有關
傳統計算法 (Harris)
 假設鋼珠軸承，基於接觸力學及實驗數據得出
 計算出來的值遠高於實驗值
 可能原因：現時高速主軸，常使用陶瓷滾珠，硬度提高、
熱產生減低
軸承產生熱量實驗
Coast test
 已知值：心軸慣性矩
 斷電、煞車關
 減速可假設單由軸承帶來
Validating thermal spindle model: case study

Measure
 Motor power consumption
 Temperature at different
locations
 Coolant flow rate
 Coolant temperature
 Coolant pressure

Source: Bossmann and Tu (1999)

Thermal balance: case study

Air
convection
Maximum power = 32 kW
254 W
Maximum speed = 25 000 rpm (1.5 × 106 DN)
Energy balance at idling
Heat
Air
conduction at
in spindle
support
81 W Heat 106 W
Front bearings dissipation
373 W 2443 W
Motor Rear bearings
stator 160 W
Cooling
1887 W water Motor air
450 W
Total heat 1552 W
generation
2445 W
Source: Bossmann and Tu (1999)
Thermal expansion
Thermal expansion coefficient of steel ≈ 10−5 /K
Case Study
Temperature distribution depends on cooling channel arrangement

Temperature
Example: 來回水道 distribution
 易造成溫度不平均
 可改為螺旋水道

Thermal deformation

Temperature distribution (solid) Temperature deformation

側向變形
Secondary effects of thermal bending

Huang et al. (2016)

 Roberto Silva, “Direct Coupled Thermal-Structural Analysis in ANSYS WorkBench” (2013)

多重物理耦合 Multiphysics Coupling

Multiple physical laws interact in real
machines. Some phenomena cannot be
studied using analysis of a single set of
physical relationship
Thermal-structural coupling is covered
• Other types of coupling include
air-structure, magnetic-structure,
etc.
Examples of thermal-structural Coupling

T S
T S

S T Involves coupling in both

directions, usually solved by
Involves coupling in one direction only, usually 2-way or direct coupling
solved by sequential 1-way coupling
例：ANSYS Workbench 熱固耦合模態分析
桿件因加溫產生熱變形，使桿件產生預應力，改變結構自
然頻率。
Internal stresses in a column arise due to thermal deformation,
and this will change the natural frequency of the structure
 方法：ANSYS Workbench

穩態熱分析 靜態分析 模態分析

(計算溫度場) (計算熱應力) (自然頻率)
Step 1: Steady-State thermal
Steady-State Thermal
1. Build mesh
2. Add convection conditions (空氣接觸條件) (如 Convection ->
Stagnant Air)
3. Add temperature conditons (選擇Temperature)

 溫度分布結果 Results
Step 2: Static Structural
Block diagram

Set boundary condionts 設定邊界條件 (e.g. Fixed-

fixed beam)

Analysis results
Step 3: Modal
預應力影響自然頻率
Study effect of internal stress on natural frequencies
Thermal analysis with ANSYS FSI

2-way system coupling

 2-way thermal
Standard CHT simulations in CFD
Assumption: No structural deformations
 2-Way Thermal and Structural
Both solvers run, exchange temperatures, heat
fluxes, forces and displacements
Coupled field elements in ANSYS Mechanical

(Source: Foley 2012)

Sequential vs Direct Coupling
Sequential coupling Direct coupling

In ANSYS
T S S T T S
Possible Impossible only in ADPL (Command-based)
Remark: Multiphysics spindle model
Detailed physical mechanism unnecessary
 Assign key parameters as “design variables” (DV)
Improving spindle design
 Sensitivity-based method
 Taguchi-based method

Source: Lin and Tu (2007)

Revision questions
1. 如何計算主軸之DmN 值?
2. 感應式馬達之轉速與電源頻率的關係？
3. S1 與 S6的負載差異為何?
4. 利用 Euler Bernoulli beam+spring 模型計算
靜剛性之誤差為何?
5. 利用 coast test 找出前端軸承的摩擦扭矩之
假設為何?
6. 那種熱變形最難解決? 有甚麼情況下會發
生? 試舉例說明。
7. 請描述軸承剛性受何因素影響。
8. 為何需要進行雙平面動平衡呢?
9. 請指出右圖的斜線的意義。
10. 如何畫出Campbell 圖? 須提到XY軸物理量
及圖中兩類線的意義。
11. 在車削中，切削力與甚麼有關?為何它不是
固定值?
Revision questions
1. How is DmN value determined?
2. What is the relationship between rotor speed and power supply
frequency in induction motors?
3. What are the difference(s) between S1 and S6 duty cycles?
4. What are the errors involved by calculating spindle stiffness using
a model based on Euler Bernoulli beam and springs?
5. What are the assumptions by determining friction torque of
front bearings using coast tests?
6. Which type of thermal deformation is difficult to compensate?
Why does it happen? Give an example.
7. What are the factors affecting bearing stiffness?
8. Why is two-plane balancing needed?
9. Explain the physical significance of slanted lines on the right.
10. How to draw a Campbell diagram? You need to mention the
physical quantities of the axes and distinguish the two group of
lines in the diagram.
11. What are the parameters involved in cutting force in turning?
Why is it time-varying?