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

Kód výsledku v 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>

Výsledek na webu

<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>

Jazyk výsledku

angličtina

Název v původním jazyce

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

Popis výsledku v původním jazyce

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.

Název v anglickém jazyce

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

Popis výsledku anglicky

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.

Druh

J_imp - Článek v periodiku v databázi Web of Science

CEP obor

—

OECD FORD obor

20301 - Mechanical engineering

Projekt

—

Návaznosti

S - Specificky vyzkum na vysokych skolach

Rok uplatnění

2025

Kód důvěrnosti údajů

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

Název periodika

Machines

ISSN

—

e-ISSN

2075-1702

Svazek periodika

13

Číslo periodika v rámci svazku

12

Stát vydavatele periodika

CH - Švýcarská konfederace

Počet stran výsledku

20

Strana od-do

—

Kód UT WoS článku

001647072700001

EID výsledku v databázi Scopus

2-s2.0-105025896324