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Key Laboratory of Education Ministry for Modern Design and Rotor-Bearing System, Xi'an Jiaotong University, Xi'an 710049, China
State Key Laboratory for Manufacturing System Engineering, Xi'an Jiaotong University, Xi'an 710049, China
a r t i c l e i n f o
a b s t r a c t
Article history:
Received 5 June 2015
Received in revised form
9 November 2015
Accepted 15 December 2015
Available online xxx
Transient analysis by thermal network method for complex structures like the spindle-bearing system is
essential but insufcient. In this paper, the network approach was developed for spindle transient
analysis in consideration of thermal-structure interaction. Firstly, the radial and axial deformation of
spindle system during assembling process, deformation by thermal extension and centrifugal effect were
all obtained. Then the transient analysis was deduced based on traditional steady model, the thermaldeformation coupling and some other time-varying parameters. Experiment results indicate that temperature by steady model is of large deviation, while by the transient model is much more accurate.
Finally, the temperature rising curves, the balance time of the spindle system and temperature rise
feature for continuous working conditions were all achieved and discussed.
2015 Elsevier Masson SAS. All rights reserved.
Keywords:
Transient thermal analysis
Thermal-deformation coupling
Spindle-bearing system
1. Introduction
Transient thermal analysis and temperature rise monitoring for
spindle-bearing system, especially high precise system, is crucial in
the design and optimization stage. The rotating spindle is a thermal
time-varying system, in which the lubricant viscosity, heat sources
and boundary conditions are all variable, depends on its temperature distribution. Meanwhile, the complex structure deformation,
induced by thermal stress, centrifugal stress and other stresses
(such as stress induced during the installation process, hereinafter
referred to as assembling stress), affects the system thermal and
precise feature. The tolerance by thermal deformation is more than
50% of the total error [1]. Therefore, transient thermal analysis, in
consideration of the thermal-deformation coupling, is much
needed for spindle-bearing system.
Many contributions for spindle thermal analysis were conducted based on nite element method, such as J. Cao [2] and J. You
[3]. The steady thermal analysis of a mechanical spindle was
investigated by T. Holkup [4], the temperature distribution and
deformation for spindle in different bearing arrangement situation
was obtained. Thermal induced preload and spindle system
stiffness were also discussed. Similarly, the work by J.F. Tu [5] gives
settlement ways, which were veried by experimental test, for
steady and transient analysis in condition of different thermal
boundary. In addition, E. Creighton [6] suggested the optimal
approach for spindle thermal characteristics and compensation
ways for thermal extension. Above all, for spindle thermal analysis
in both steady and transient conditions, the ways based on FEM
were theoretically well developed, but its application was limited,
due to its complicated meshing and contact pairs setting for polytropic and complex engineering problems. A thermal mechanical
coupling model was given by C.W. Lin [7] based on nite element
approach, and the stiffness change induced by centrifugal effect
was discussed. The insufcient is, the inuence of bearing stiffness
on its thermal feature was neglected. Another thermal mechanical
model by H.Q. Li and Y.C. Shin [8e11] contains three parts, the
nonlinear bearing, spindle and thermal model, which can be used
to predict the static and dynamic stiffness, temperature distribution and bearing contact load. However, the centrifugal effect and
bearing gyroscopic effect were lacked in their model. Y.Z. Cao and Y.
Altintas [12] analyzed the relationship between spindle stiffness
and preload, by integrating the Jones' bearing model and spindle
model via FEM. And the dynamic characteristics of spindle system
in both xed-pressure and xed-position pretension condition
were studied [13,14]. However, the extension and thermal deformation during spindle rotation were ignored in all the above
models. The spindle dynamic model and thermal model were all
Nomenclature
a,b,c..f
A
B
C
Db
D
d
d1
d2
E
Fa
h
L
K
p
q
Q
R
R
T
DT
u
V
Greek letters
a
contact angle/rad
b
thermal extension coefcient/K1
m
poisson ratio
l
thermal conductivity/W(mm K)1
v
viscosity/mm2 s1
r
density/kg m3
u
angular velocity/rad s1
s
stress component/Pa
d
deection/mm
strain component
j
tolerance
structural size/mm
area/mm2
bearing total curvature
specic heat/J$(kg K)1
bearing balls' diameter/mm
bearing external diameter/mm
bearing internal diameter/mm
inner ring external diameter/mm
outer ring internal diameter/mm
elasticity modulus/Pa
axial load/N
heat transfer coefcient/W$(mm2 K)1
bearing axial size/mm
axial displacement constant
assembling stress/Pa
heat ux/W m2
heat source/W
shaft radius/mm
thermal resistance/K W1
temperature/K
temperature difference/K
structural deformation/mm
volume/m3
Subscript
0
i
o
l
r
h
b
g
s
balls'number
original
inner ring
outer ring
axial direction
radial direction
housing
bearing
grease
shaft
bearing inner ring are b and c, for outer ring are d and e, respectively. The housing outer radius is denoted as f. The steady temperature values for the above subassemblies are T1, T2, T3, T4, T5, T6,
in sequence.
dsr sr sq
ru2 r 0
dr
r
(1)
du
dr
u
r
E
sr
r vq 1 mb$DT
1 m2
(3)
E
q vr 1 mb$DT
1 m2
(4)
d2 u 1 du u
dDT 1 m2 2
1 mb
ru r
dr
E
dr 2 r dr r 2
(5)
DT DTi
DTo DTi
lnr=ri
lnro =ri
3mru2 r 2
8
(8)
p1
Ed1 c2 b2 b2 a2
2b3
c2 a2
(9)
For inner surface of inner ring, the stress in radial direction is p1,
and the outer surface is free face. So the boundary conditions for
bearing inner ring can be described as:
(10)
Substituting the above boundary conditions into Eq. (8), and one
obtains the constants C1 and C2:
C1
C2
i
1m h
8p1 b2 3mru2 c4 b4
2
2
8E c b
b1v 2k4n b2 c2 4k c2 lncb2 lnb
8 c2 b2
(11)
i
1 mc2 b2 h
8p1 3 mru2 c2 b2
2
2
8E c b
b2 c2 1 m
kbln c ln b
2 c 2 b2
(12)
(6)
Substituting Eq. (6) into Eq. (5) and integrates, then one obtains
the expressions of radial deformation and stress:
bE
E
1m
nk$lnrk=2
C
1mC
1
2
2
1m2
r2
r b; sr p1 ; r c; sr 0
(2)
sq
sr
1 mb
C
1 m2 ru2 r 3
rn k$ln r k=2 C1 r 2
2
r
E
8
(7)
Ed f 2 e2 e2 d2
p2 23
2e
f 2 d2
(13)
For outer surface of bearing outer ring, the stress in radial direction is p2, and the inner surface is free face. So the boundary
conditions can be described as:
r d; sr 0; r e; sr p2
(14)
r e; sr p2 ; r f ; sr 0
(15)
Based on the stress expressions in Eqs. (11) and (12), the corresponding constants can be derived by the above boundary expressions. Then similarly, the radial deformation of outer ring and
housing can be calculated by Eq. (7).
2.1.3. Shaft neck
The axial length of spindle shaft is much larger than the sizes of
its cross section, so the radial deformation of spindle shaft is
equivalent to a beam with uniform cross section. Based on the
equations for plane stress problem, replace the constants E, b, m
with E/(1m2), b(1m) and m(1m), then one obtains the corresponding plane strain equations.
Based on Eqs. (7)e(8), the radial deformation and stress for
plane stress problem can be achieved via the above transformation:
u2
1 mb
C
rn2 k2 $ln r k2 =2 C3 r 4
21 m
r
sr2
1 m1 2m ru2 r 3
E1 m
8
bE
E
C3
C
n2 k2 $lnrk2 =2
24
21m
1m 12m r
32mru2 r 2
81m
(16)
(17)
r a; sr 0; r b; sr p1
(18)
C3
Substituting C3 and C4 into Eq. 16 and 17, one obtains the total
radial deformation of spindle shaft.
2.2. Bearing preload and axial deformation
As known to all, system axial deformation and preload inuent
each other. The installation process affects bearing initial preload,
and the preload affects axial deformation and bearing frictional
heat. Then thermal deformation by frictional heat alters its preload,
vice versa. Hence the interaction between preload and axial
deformation should be calculated in spindle-bearing system transient thermal analysis.
2.2.1. Axial assembling deformation on additional preload
For a given spindle system with two front and two rear bearings,
back to back installation with xed-position pre-tightening (the
spindle structure will be illustrate in the sections below). The
preload was adjusted by high precise and high stiffness spacers. The
interaction of the two bearings in the same end can be treated as
tandem bearings, seen in Fig. 2. The total preload force is Fa, while
for the rear bearing is Fa2. During the installation process, bearing
rings width size and deviation are W, J1 and J2, for spacer bush
they are L, J3 and J4, respectively. During the preloading
procedure, in case the rear bearing is preloaded rst, and its out
ring axial deformation equals Dd. Because the deformation is
induced by tolerance between outer ring and spacer bush, the
deformation is among the follow range:
a1m12m2k 4n b2 a2 4k a2 lnab2 lnb
1m12m
32m 2 4
2
2
4
2
8p1 b2
ru
b
a
1m
8E b2 a2
8 a2 b2 1m
0 Dd 2j1 j2 j3 j4 Dd sin a
C4
1 ma2 b2
3 2m 2 2
2
8p1
ru
b
a
1m
8E b2 a2
a2 b2 1 m
2
k2 bln a ln b
2 a b2 1 m
(20)
(19)
(21)
da2 Dd da1
(22)
Fa2
ZKn2 Bf2 1:5
da2
sin a2
1:5
cos a02
1
cos a2
(23)
(24)
an1
2
Fp1
1:5
ZKn1 n Bf2
an2
sin an2
!2 "
cos a02
cos an2 1
sin 2an2
cos a02
cos an2 1
!
cos a02
cos an2 1
gradient are all variable around and inside the contact area, and the
transient thermal feature is directly affected. In order to consider
these factors in transient analysis, nodes distribution was modied
in this paper, seen in Fig. 3(b) and (c).
In Fig. 3(b), a ve-node model was proposed to consider temperature difference of rings, and in Fig. 3(c), a seven-node model
was presented to study the thermal difference of subassemblies
and also the vicinal lubricant. For the three-node model, the
resistance, i.e. the contact thermal resistance [31], between balls
and rings can be written as:
#
2
(26)
(27)
where us means thermal deformation difference, mm, T is temperature rise, K, l denotes the axial sizes of bearing inner/outer
rings, mm.
Bearing installation given in this paper is back to back
arrangement, so the difference of thermal deformation is contrary
to the initial displacement. Hence the total axial displacement is,
ua u0 us
(28)
Figure out balls' diameter Db1 and total curvature B1 after thermal extension, substituting them into the thermal displacement
equation, and the real contact angle a0 can be obtained:
B D sina0 a0
ua 1 b1
cos a0
(29)
1:5
cos a
Fa
0
1
sin a0
2
cos a0
ZDb1 K
lnD=d2
Ro
2plb l
(31)
Rsi
(25)
Rbo
sin an
Bf sina a0
u0
cos a
lnd1 =d
Ri
2plb l
Rib
!3
!2
(30)
lnd1 =d
Rib
2plb l
Rbo Ro
Roh
lnD=d1
2plb l
Rib Ri
(32)
(33)
For the seven-node model, heat resistance Rs-i, Ro-h are the same
with the above model, and other resistance can be expressed as:
Rig Ri
Rgo Ro
(34)
Rgb
lnd2 =d1
2plg l
(35)
Rc d=lA
Rv 1=hA
(36)
RL
4L
lp D2 d2
Rr
lnD=d
2plL
(37)
Rhl
4
hp D2 d2
Rhr
1
hpDL
(38)
Ri
Ro
plg
Db
.
d1 l ZD2b 4
Db
.
2plg d2 l ZD2b 4
(39)
(40)
To T1 To T2 To T3 To T4
Qf
Ro1
Ro2
Ro3
Ro4
(42)
4
4
X
X
1
1
To
Ti Qf
R
R
i1 oi
i1 oi
Q DT=R
(41)
GfTg fQ g
(43)
(44)
Fig. 4. Heat transfer mechanism of a thermal node and its adjacent nodes.
dT
qi Ci ri Vi i
dt
(45)
In which dTi/dt means the temperature rise rate at the ith node.
According to the energy conversation principle, transient thermal balance equation of a node in two-dimensional system can be
developed:
To T1 To T2 To T3 To T4
dTo
Qfo Co ro Vo
Ro1
Ro2
Ro3
Ro4
dt
(46)
In order to achieve the transient temperature eld, the continuous value t was discretized by time series of certain step size Dt:
tk1 tk Dtk
(47)
Tik1 Tik
dTik
Dtk
dt
(48)
Substituting Eq. (48) into Eq. (46), one obtains the arithmetic
solution of the transient thermal balance equation for one node:
Ro1
Ro2
Ro3
Ro4
Qfo Co ro Vo
Tok1 Tok
Dtk
(49)
4. Experiment
4.1. The experimental rig
The experiment was conducted in the United Laboratory of NSK
and Xi'an Jiaotong University. The machine tool spindle system,
WZ15B90-30SE mechanical spindle, was shown in Fig. 7. The
schematic view of the spindle can be seen in Fig. 5. The rotation
range is from 2000 to 8000 r/min. The NSK 7014CTYNSULP4
bearing was used, two front and two rear with back to back
arrangement. The lubricant is grease NSK MTE. The xed-position
pre-tightening was chose with an initial preload 1400 N. Before
installation, the relationship between spacer's position/size/length
and bearing's contact angle/preload was deduced. During the pretightening process, the position of the spacers was adjusted to
obtain proper bearing preload.
During the testing, the thermal balance criterion is: temperature
variation in one minute is less than 0.2 C. The temperature of
bearing outer ring was captured by a thermocouple sensor MISUMI
every two seconds, the resolution is 0.1 C. The thermocouple
sensor was contact with bearing outer ring through an axial
clearance hole of the front end cover. The MISUMI thermocouple
sensor is a closed circuit composed of two different conductor
materials. When temperature gradient exists, current and electromotive force inside the circuit occur, which reect temperature
value via certain relationship. The displacement of housing was
monitored by capacitive sensor C8-2.0, which standard measuring
range is 250 mm. Three displacement sensors were used (two for
radial and the other for axial displacement) and the monitoring
data was output by Lion data acquisition system.
For thermal analysis, heat transfer coefcient is crucial in the
calculation. The empirical equation for heat transfer coefcient is
proved to be much deviated from the real value, hence the natural
heat transfer coefcient of the spindle surface was measured by
temperature-gradient heat ux sensor. Then the testing data was
used instead of the empirical equation during the above calculation. The Capter ultrathin sensor HS-9010 was chose because the
spindle surface is curved. The monitoring data was output by
MX100 data acquisition system. The sensor resolution is
8.2 mV (W m2)1, its responding time and operating temperature
are respectively 0.3 s and 180 to 200 C.
4.2. Testing procedure
After the arrangement process and run-in period, the radial play
eccentricity of the shaft was adjusted rst. Then the spindle was set
a given rotation speed and started. The natural heat transfer coefcient and housing temperature were all monitored until thermal
equilibrium (The criterion is: temperature variation in the same
place is less than 0.2 C in a minute). When the testing in a given
speed is completed, the spindle system was shut down to the room
temperature, and then the next step was carried out. During the
measurement, outer ring temperature, natural heat transfer
about 10% at 2000 r/min (9.6% and 13.4%, respectively). When the
rotation speed rise, the deviations increase up to 30% (30% and 38%
at 6000 r/min, 25.7% and 33.4% at 8000 r/min). That's because,
during the calculation, heat dissipation by lubrication and air ow
inside bearing cavity was ignored, which plays an important role in
bearing heat transfer, especially at relatively higher speed. The
result by ve-node model is even larger than the traditional threenode model, due to the enhancement of heat transfer but ignorance
of heat dissipation. In the seven-node model, the grease characteristic was considered, and the result is more close to the real one,
the tolerance is less than 12% (11.6% and 12% for rotation speed
Based on the seven-node bearing model, the thermal characteristics by steady and transient approaches were compared to the
experimental data, seen in Fig. 10. During the transient calculation,
three different procedures were carried out in order to understand
the inuence of different factors: 1) iteration calculation, during
this process only the iteration method was considered. That is, the
thermal deformation and viscosity effect were all ignored; 2)
temperature viscosity feature was added into the iteration calculation; 3) complete transient analysis process, thermal deformation
and viscosity were all discussed during the transient iteration
computation. From Fig. 9, temperature by steady model is much
higher than experiment data. For transient model, the inuence of
iteration and viscosity are most obvious because their large deviation to the steady results. So it can be derived that, the tolerance by
steady method is mostly due to its constant parameter in heat
transfer calculation. Based on different procedure of transient
analysis, the inuence of thermal parameter on temperature is
small at low rotation speed. In the other hand, when the rotation
speed increasing, the temperatureeviscosity effect and thermal
deformation increase, hence their inuence on spindle temperature increases.
5.4. Stress effect on deformation
In order to understand the effects of thermal stress, assembling
stress and centrifugal stress on spindle radial deformation, the inner ring deformation was calculated in different rotation speed and
arrangement magnitude. The radial deformation of inner ring under individual effect of the three stresses was shown in Figs. 11 and
12.
From Fig. 11, deformation induced by assembling process remains the same at different rotation speed, that's because the
deformation occurs only in the spindle arrangement process.
Conversely, Thermal and centrifugal effects increase greatly at high
rotation value, because the spindle temperature and centrifugal
force grow as well. Thermal and centrifugal deformation here
means structural deformation induced thermal extension and
centrifugal force, respectively. For different arrangement magnitude in Fig. 12 at rotation speed 6000 r/min, the centrifugal force
remains unchanged due to its inherent feature with subassemblies
motions. Therefore the centrifugal deformation keeps constant at
certain rotation speed. In the design stage of spindle-bearing system, a smaller interference t magnitude is benet to its deformation. However, due to the thermal and centrifugal effects, the
interference t magnitude between shaft and inner ring decreases,
so a small magnitude may lead to loosening problem. Hence the
choice of spindle-bearing interference magnitude is important.
Among the three effects, thermal stress contributes the most to
the total deformation. Therefore, thermal extension is the major
factor for spindle deformation. For centrifugal effect and assembling deformation, the effects depend on spindle rotation speed
and arrangement conditions.
5.5. Balance time
10
Table 1
Comparison of radial deformation of bearing housing.
Rotation speed (r/min)
2000
4000
6000
8000
Environment temperature ( C)
16.5
18.5
16.8
17.1
2.40
5.10
7.92
11.42
Tolerance (%)
Transient
Steady
Transient
Steady
2.26
4.87
7.07
9.27
3.75
6.85
11.03
15.24
5.8
4.5
10.7
18.8
56.0
34.3
39.3
33.5
11
Table 2
Balance time and bearing outer ring temperature at different rotation speed.
Rotation speed (r/min)
Environment temperature ( C)
Balance temperature ( C)
Temperature rising ( C)
2000
2000
4000
4000
6000
6000
8000
8000
16.5
19.8
18.5
18.9
17.9
18.4
17.1
21.6
18.9
22.0
22.8
22.8
26.8
27.0
30.9
34.6
2.4
2.2
4.3
3.9
8.9
8.6
13.8
13
67
63
56
55
50
48
38
29
6. Conclusion
In this paper, the network approach was developed for spindle
transient analysis in consideration of thermal-structure interaction.
The improved models for bearing and system were studied and the
tested natural heat transfer parameter was employed in the
calculation. Based on experimental verication, the transient
model was proved to be more superior to the steady approach. The
conclusions of the article are as follow:
1) A transient thermal network model was developed for complex
structure analysis, such as spindle-bearing system. The thermalstructure coupling (time-varying parameters like deformation,
viscosity, etc.) was considered in transient analysis.
2) Compared to the steady model, the inuence of iteration and
viscosity in transient analysis are dominating. Hence the tolerance by steady method is mostly due to its constant parameters
in heat transfer calculation.
12
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