Combination of finite element spindle model with drive-based cutting force estimation for assessing spindle bearing load of machine tools

Result code in IS VaVaI

<a href="https://www.isvavai.cz/riv?ss=detail&h=RIV%2F00216305%3A26210%2F26%3A0199882" target="_blank" >RIV/00216305:26210/26:0199882 - isvavai.cz</a>

Result on the web

<a href="https://www.mdpi.com/2075-1702/13/12/1138" target="_blank" >https://www.mdpi.com/2075-1702/13/12/1138</a>

DOI - Digital Object Identifier

<a href="http://dx.doi.org/10.3390/machines13121138" target="_blank" >10.3390/machines13121138</a>

Result language

angličtina

Original language name

Combination of finite element spindle model with drive-based cutting force estimation for assessing spindle bearing load of machine tools

Original language description

Monitoring spindle bearing load is essential for ensuring machining accuracy, reliability, and predictive maintenance in machine tools. This paper presents an approach that combines drive-based cutting force estimation with a finite element method (FEM) spindle model. The drive-based method reconstructs process forces from the motor torque signal of the feed axes by modeling and compensating motion-related torque components, including static friction, acceleration, gravitation, standstill, and periodic disturbances. The inverse mechanical and control transfer behavior is also considered. Input signals include the actual motor torque, axis position, and position setpoint, recorded by the control system’s internal measurement function at the interpolator clock rate. Cutting forces are then calculated in MATLAB/Simulink and used as inputs for the FEM spindle model. Rolling elements are replaced by bushing joints with stiffness derived from datasheets and adjusted through experiments. Force estimation was validated on a DMC 850 V machining center using a standardized test workpiece, with results compared against a dynamometer. The spindle model was validated separately on a MCV 754 Quick machine under static loading. The combined approach produced consistent results and identified the front bearing as the most critically loaded. The method enables practical spindle bearing load estimation without external sensors, lowering system complexity and cost.

Czech name

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Czech description

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Type

J_imp - Article in a specialist periodical, which is included in the Web of Science database

CEP classification

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OECD FORD branch

20301 - Mechanical engineering

Project

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Continuities

S - Specificky vyzkum na vysokych skolach

Publication year

2025

Confidentiality

S - Úplné a pravdivé údaje o projektu nepodléhají ochraně podle zvláštních právních předpisů

Name of the periodical

Machines

ISSN

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e-ISSN

2075-1702

Volume of the periodical

13

Issue of the periodical within the volume

12

Country of publishing house

CH - SWITZERLAND

Number of pages

20

Pages from-to

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UT code for WoS article

001647072700001

EID of the result in the Scopus database

2-s2.0-105025896324