Stability-Based Spindle Design Optimization

[+] Author and Article Information
Vincent Gagnol

 LAMI-Mechanical Engineering Research Group, BP 265, 63175 Aubière Cedex, Francevincent.gagnol@ifma.fr

Belhassen C. Bouzgarrou

 LAMI-Mechanical Engineering Research Group, BP 265, 63175 Aubière Cedex, Francechedli.bouzgarrou@ifma.fr

Pascal Ray

 LAMI-Mechanical Engineering Research Group, BP 265, 63175 Aubière Cedex, Francepascal.ray@ifma.fr

Christian Barra

 PCI-SCEMM, rue COPERNIC, 42000 Saint-Étienne, Francechristian.barra@pci.fr

J. Manuf. Sci. Eng 129(2), 407-415 (Nov 08, 2006) (9 pages) doi:10.1115/1.2673400 History: Received February 20, 2006; Revised November 08, 2006

Prediction of stable cutting regions is a critical requirement for high-speed milling operations. These predictions are generally made using frequency-response measurements of the tool-holder-spindle set obtained from a nonrotating spindle. However, significant changes in system dynamics occur during high-speed rotation. In this paper, a dynamic high-speed spindle-bearing system model is elaborated on the basis of rotor dynamics prediction and readjusted on the basis of experimental modal identification. The dependency of dynamic behavior on speed range is then investigated and determined with accuracy. Dedicated experiments are carried out in order to confirm model results. They show that dynamic effects due to high rotational speed and elastic deformations, such as gyroscopic coupling and spin softening, have a significant influence on spindle behavior. By integrating the modeled speed-dependent spindle transfer function in the chatter vibration stability approach of Altintas and Budak (1995, CIRPS Ann, 44(1), pp. 357–362), a new dynamic stability lobe diagram is predicted. Significant changes are observed in the stability limits constructed using the proposed approach and allow accurate prediction of cutting conditions to be established. Finally, optimization studies are performed on spindle design parameters in order to obtain a chatter vibration-free cutting operation at the desired speed and depth of cut for a given cutter.

Copyright © 2007 by American Society of Mechanical Engineers
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Figure 1

The HSM spindle bearing system

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Figure 2

Finite element model of the spindle-bearing system

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Figure 3

Algorithm of numeric model readjustment

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Figure 4

Experimental, initial, and readjusted numeric FRF

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Figure 5

3D speed-dependent frequency response function

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Figure 6

Experimental setup

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Figure 7

Comparison between recorded radial tool vibration and Campbell diagram prediction

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Figure 8

Self-excited vibrations in the spindle milling system

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Figure 9

Spindle dynamics-based stability lobe diagram algorithm

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Figure 10

Static and dynamic model-based lobe diagram comparison

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Figure 11

Machining test setup

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Figure 12

Stability determination by sound spectrum analysis

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Figure 13

Modeled stability lobes, compared to experimentally performed cuts

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Figure 14

Initial spindle design

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Figure 15

Spindle design configurations at different stages of the optimization process

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Figure 16

Stability lobe for initial, intermediate, and optimized spindle design

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Figure 17

Configuration of competing spindles

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Figure 18

Comparative spindle stability lobe diagram



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