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Research Papers

Coupled Model of Rotary-Tilting Spindle Head for Pose-Dependent Prediction of Dynamics

[+] Author and Article Information
Chao Du, Jun Zhang, Dun Lu, Huijie Zhang

School of Mechanical Engineering,
Xi'an Jiaotong University,
Xi'an 710049, China;
State Key Laboratory for Manufacturing
Systems Engineering,
Xi'an Jiaotong University,
Xi'an 710049, China

Wanhua Zhao

School of Mechanical Engineering,
Xi'an Jiaotong University,
Xi'an 710049, China;
State Key Laboratory for Manufacturing
Systems Engineering,
Xi'an Jiaotong University,
Xi'an 710049, China
e-mail: whzhao@mail.xjtu.edu.cn

1Corresponding author.

Manuscript received August 3, 2017; final manuscript received April 25, 2018; published online June 1, 2018. Assoc. Editor: Satish Bukkapatnam.

J. Manuf. Sci. Eng 140(8), 081008 (Jun 01, 2018) (16 pages) Paper No: MANU-17-1495; doi: 10.1115/1.4040155 History: Received August 03, 2017; Revised April 25, 2018

Five-axis machine with rotary-tilting spindle head (RTSH) is always used for sculptured surface machining, and the tool-tip dynamics in various machining postures along the tool path directly affect the machining accuracy and stability. To rapidly evaluate the tool-tip dynamics at different postures during the structural design of tool-spindle-spindle head (TSSH) assembly, this paper proposes a coupled dynamic model of tool-spindle-bearing system (TSBS) and RTSH. The model is a rigid-flexible multibody dynamic model with 36 degrees-of-freedom (DOFs), where in the rotary shaft, swivel shaft and housing are treated as rigid bodies; the tool, tool holder, and spindle shaft are modeled by reduced beams; the bearings and flexible joints are modeled as spring-damping elements. The fully Cartesian coordinates and Lagrangian method are employed to deduce a general parametric dynamic equation. The analytical method for calculating the contact stiffness of bearings and flexible joints is systematically presented, including tool-holder joint, holder-spindle joint, spindle bearings, hirth coupling, and the bearings and locking joints of rotary and swivel shafts. The model is verified by the frequency response functions (FRFs) testing and modal testing at different postures. The experimental results show that the proposed model can be used for accurate and efficient evaluation of the tool-tip FRFs, natural frequencies and mode shapes of TSSH at an arbitrary posture.

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Figures

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Fig. 1

Tool-spindle-spindle head assembly: (a) geometric model, (b) dynamic model, and (c) calculating model

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Fig. 2

Tool-spindle-bearing system: (a) geometric model, (b) FE model, and (c) 18DOF reduced model

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Fig. 3

Joints of tool system: (a) structure diagram, (b) tool-holder joint, (c) taper contact joint, and (d) flange contact joint

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Fig. 4

Force diagram of clamped tool holder: (a) clamping force of drawbar finger and (b) clamping force of tool holder

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Fig. 5

Force diagram of the rotary shaft bearing

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Fig. 6

Force diagram of the swivel shaft bearing

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Fig. 7

Force diagram of the hirth coupling

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Fig. 8

Impact testing experiment: (a) tool-tip FRF testing and (b) modal testing

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Fig. 9

Comparison of tool-tip FRFs between FE model and reduced model

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Fig. 10

Tool-tip FRFs of experiment and simulation at θA = 0 deg: (a) xx FRFs and (b) zz FRFs

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Fig. 11

Tool-tip FRFs of experiment and simulation at θA = 90 deg: (a) xx FRFs and (b) zz FRFs

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Fig. 12

Mode shapes of experiment: (a) 401 Hz, (b) 457 Hz, (c) 188 Hz, and (d) 449 Hz

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Fig. 13

Mode shapes of simulation: (a) 433 Hz, (b) 483 Hz, (c) 182 Hz, and (d) 453 Hz

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Fig. 14

Tool-tip FRFs of the TSSH at different swivel angles: (a) xx FRFs and (b) zz FRFs

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