ADAPTIVE COOLING SYSTEM

FOR VMC SPINDLE

Guided by:

Dr. B. Giriraj A.P. Arun

Senior lecturer R. No. 07MI31
Department of Mechanical Engineering ME CIM
 FLOW OF PRESENTATION

Problem definition
Literature survey
Objective
Proposed solution
Methodology
Conclusion and further work
 PROBLEM DEFINITION

High-speed machining has become the mainstream of

metal cutting. To achieve this goal, the rotational speed of the
spindle must be increased. Thermally induced errors are
significant factors affecting machine-tool accuracy. These
thermal errors have been reported to be about 70% of the
total positioning errors in machine tools[8]

According to the data of FAG (Germany), with the

installation of high-precision bearings in the spindle assemblies
of the machine tools, the temperature of the spindle bearings
should not exceed 50–60° (temperature rise of 30–40°C), while
for the very-high-precision machines the temperature should
not exceed 30–40°C(temperature rise of 10–20°C).

During continuous running of machine with normal

cooling system the spindle was over cooled causing significant
shrink in the spindle. The resultant distortions are revealed in
the motion of spindle relative to the machine frame.

Equipment Operating for worst condition continuously,

or cycling it on and off, is a sub optimal solution in most
cooling applications.
 LITERATURE SURVEY
SPINDLE THERMAL DISPLACEMENT

[1] Zone-Ching Lin ,et al., The building of spindle thermal displacement
model of high speed machine center, International Journal of Advanced
Manufacturing Technology, 2007, Vol :34, Page No. 556–566

[2] S.-M. Kim ,et al., Spindle Housing Design Parameter Optimization
Considering Thermo-Elastic Behaviour International Journal of Advanced
Manufacturing Technology, 2005, Vol: 25, Page No. 1061–1070

[3] S.-M. Kim, et al., Effect of Bearing Surroundings on the High-Speed

Spindle-Bearing Compliance, International Journal of Advanced Manufacturing
Technology, 2002, Vol:19, Page No.551–557

[4] V Prabhu Raja, et al., Prediction of Thermal Deflection at Spindle Nose-

tool Holder Interface in HSM ,2001

[5] Hayato YOSHIOKA, et al., Minimising thermal deformation of

aerostatic spindle system by temperature control of supply air, JSME International
Journal, 2006,series C, Vol. 49, Page No. 2
 BEARING EFFECTS ON SPINDLE

[6] S.-M. Kim, et al., Effect of Bearing Surroundings on the High-Speed

Spindle-Bearing Compliance, International Journal of Advanced Manufacturing
Technology,
2002, Vol:19, Page No.551–557

[7] Hongqi Li, et al., Analysis of bearing configuration effects on high

speed spindles using an integrated dynamic thermo-mechanical spindle model,
International Journal of Machine Tools & Manufacture, 2004, Vol:44, Page
No.347–364
BRICATION OF SPINDLE

[8] Cheng-Hsien Wu, et al., A parametric study on oil/air lubrication of a high-speed

ndle, Precision Engineering, 2005, Vol:29, Page No.162–167

REAL TIME SPINDLE HEALTH MONITORING

[9] H. J. Pahk et al., Thermal Error Measurement and Real Time

Compensation System for the CNCMachine Tools Incorporating the Spindle Thermal
Error and the Feed AxisThermal Error,International Journal of Advanced
Manufacturing Technology , 2002, Vol:20, Page No.487–494

[10] Li Zhang, et al., Design of a Real-time Spindle Health Monitoring and

Diagnosis
 OBJECTIV
E
The objective of this project is to minimize the thermal distortion of spindle
using adaptive cooling system. To accomplish this objective the specific sub-objectives
of this project were as follows

• Identification of sources of heat, which results in spindle

distortion.

• To develop a adaptive cooling system using graphical programming

Software (LabVIEW).

• To test adaptive cooling system for improvement.

 VERTICAL MACHINING CENTER
CNC milling machine which has the following specification

Machine : 3-axis vertical CNC milling

Power : 5 KW

Speed : Integrated motorized spindle that can rotate up to 40,000 rpm

Bearings used in the spindle

Front bearing type 7914X2TAU (bore diameter 70mm)

Rear end bearing type 7912X2TAU (bore diameter 60mm)
 SPINDLE HEAT SOURCE

• Bearings of spindle shaft

• Electric motor
• Cutting process
• External heat sources (Ambient air,
Electrical lighting ,Sunlight ,People
,Other machines…)
The resultant distortions are revealed in the
motion of the spindle relative to the machine
frame.
 PROPOSED SOLUTION
To develop an adaptive cooling system for the HSM spindle number of
materials were referred based on that the following ideas were generated.

The first step is to control the flow rate of the coolant by automating
the flow control valve based on the spindle temperature with the help of
LabVIEW software. So that the equipment will be controlled to operate at
whatever condition necessary to satisfy the need of the moment.
 coolant system normally starts with the help of thermostat but it has a
disadvantage that it takes some time to switch on the cooler, this time gap is because of
the thermal expansion of the bimetallic strip in the thermostat, in-between this time gap
the spindle distortion may takes place. To avoid this and for immediate response an
on/off relay is going to be used which will be automated by LabVIEW software based on
the coolant temperature coming as outlet from the spindle .
 We can also automate the fan for condenser, where it should be controlled to operate
at whatever speed necessary to satisfy the need of the moment based on the coolant
temperature with the same LabVIEW software
BENEFITS

• minimize spindle distortion

• Energy Savings
• Increased Fan Life
• Automatic Compensation for Changes in Cooling
• Noise Reduction
• Other System Dependant Benefits
 METHODOLOGY

• Study of vertical machining center has to be done and process parameter has to
be studied.

• Experiments are to be carried out by using a 3-axis Vertical CNC milling machine
for mapping temperature rise.

• Based on the experimental data and predetermined threshold values of spindle

temperature , the coolant temperature and flow rate are to be altered using real time
adaptive cooling system to maintain spindle temperature to achieve high precision.

• The LabVIEW program will be used to receive temperature from thermocouple

and using a feedback control, the coolant temperature and flow rate are to be
controlled.

• In order to establish an adaptive cooling system the flow control valve, relay and
condenser fan were to be automated using LabVIEW.

• The thermocouples are to be interface through the input port of the Data
Acquisition Card (DAQ).

• Temperature will be acquired from DAQ through Analog input.

• Temperature value is then compared with the predefined threshold value and
if there is any change, a voltage signal of the range 0-10 v will be made available
in the output port of the DAQ.

• Using this output voltage, the flow control valve, condenser fan and relay will
be controlled automatically to maintain the flow rate, temperature and to on/off
the coolant system.

• Finally the improvement has to be made according to the previous test and
analyzed data.
 Methodology – Adaptive Cooling System

Start

Program load cycle

Mathematical model Predict the temperature CNC program

variation

Spindle health condition

monitoring

Spindle health diagnosis

Spindle optimal operation

End
 CONCLUSION AND FURTHER WORK
In order to achieve the objective of the project literature survey were taken based on
that solutions were proposed and methodology were developed to Implement the
proposed solution

Further work in this project is to find the relationship between heat developed and
spindle deformation , based on that a graphical program is to be created in LabVIEW
software.

Then this adaptive cooling system will be implemented for the vertical machining
center spindle. Finally the system is to be tested for improvement.
REFERENCES
www.machinerylubrication.com

http://www.ahrinternational.com/bearing_materials_table.h

http://www.ansys.com/events/proceedings/

http://www.yampanet.com/Technology/technology.htm

http://www.wipo.int/pctdb/en/wo.jsp?IA=WO2007019304&D
 THANK
YOU