Monitoring Of Machine Tool Spindle Assembly Using Vibration

Analysis
Vijay Rampal.S1 & Syath Abuthakeer.S2

PG Student, PSG College of technology, Coimbatore 641004, Tamil Nadu,

India,rampalmech@gmail.com

Abstract

In order to increase productivity, enhance quality and reduce cost, machine tool have to work
free of any failure. The idea of the research is to investigate the response of the spindle bearing
system with and without defect. Hear an attempt has been made by modeling the turning centre
spindle assembly using finite element software to find out the dynamic response of the system
defective bearing, defective spindle and unbalance forces. Model analysis was carried out to
define the systems natural characteristics which are the natural frequency and mode shape.
Harmonic response analysis was carried out to determine the dynamic response due to
unbalanced forces. Transient response analysis was carried out to determine the vibration level
of the system at various nodes. The FEM results were compared with the experimental values.
Thus the present work shows that the FEM is a valuable tool in finding the vibration for various
defects.

Keywords: spindle, bearing, dynamic analysis, vibration, machine tool.

1.0 Introduction

Vibration signal measured contains the hart beat of the machine tool, which, if properly
interpreted, can reveal the running condition. The resulting surface marking on the finished work
piece are related to the amplitude and frequency content of the vibration present. In the present
study, from the failure data, spindle bearing assembly has been identified as the critical
subsystem. This project is dedicated to the experimental and FEM dynamic analysis of the
spindle bearing assembly with self exited vibration.

1.1 Literature review

Mahboubkhah et al, highlights knowledge on natural frequency of a structure is required to

avoid resonance, which leads to breakdown. Claudiu et al, self exited vibration domain is
obtained through spectra of two accelerometers, one three axis accelerometer at the tool and
the other accelerometer at the front bearing for displacement analysis of self exited vibration in
turning. The cutting process of elastic machining system causes work piece tool displacement
that causes vibration, so resulting in modified chip size which reflects the dynamic instability. Six
component Dynamometer is used to measure the dynamic cutting force. The parameter which
has most effect on the amplitude response is the depth of cut, so depth of cut was increased by
every excrement and the vibrations were studied. The self exited frequency studied between
120-200 HZ. The tooltip displacement is ellipse and as the depth of cut increases the ellipse
gets larger. Nobuaki Kamimoto et al, difference in vibration pattern across various position of
the link causes vibration stresses which lead to material fatigue.

Mohammed et al. The study reveals, the larger the initial preload applied, the less vibration
amplitudes are generated, and consequently less variation in the grinding depth of cut. As the
initial preload increases, i.e., the stiffness of the bearing increases, the dominant frequencies of

1
the system shift to higher values. As the preload increases up to a certain value, the peak to-
peak amplitude decreases. Beyond this value the reduction in vibration amplitude is insignificant
which indicates that larger values of preloading will not further reduce the vibration levels of the
machine spindle. Therefore, this analysis can be used to calculate the optimum initial axial
preload in order to obtain high accuracy for surface finish. The vibration levels of grinding
machine spindle system increase significantly for grinding wheel wear rate percentage greater
than 2, and decrease as the work piece material hardness decreases. S. Saravanan et al. The
different component defects have their unique frequency, the amplitude denotes severity of the
defect and the frequency reflects the source of the defect. Modern techniques for bearing
diagnosis are directly applicable for machine tool. Gradual deterioration type of failure is suitable
for machine condition monitoring, bearing failure is one example of the above mentioned failure
type.

K N Guptha, illustrates how machine troubles/ failures are diagnosed with the help of vibration
signature. Deterioration in the operation of a machine component gives rise to increasing in
vibration level, mixing of vibration signals does not cause any loss of individual’s frequency
information. Vibration signature taken from appropriate location in machine tool can reveal the
following defects: imbalance, misalignment, imperfect foundation, rubs, bearing defects, fault in
belt drive etc. Piezoelectric transducer is lighter and has better frequency range for application,
so the accelerometers are the best choice. The measures of the time based vibration analysis
includes rms measurement, peak level (amount of impulse and bearing defect detection), crest
factor, shock pulse, kurtosis (statistical movement of the probability density function of the
vibration signal, phase). Trend analysis exhibits the rate of deterioration of vibration level in
machine tool. The vibration reference standard is VDI 2056. Frequency based vibration signal
includes spectrum, waterfall plot and cepstrum.

M.A.Mannan and B.J. Stone. The tradeoff between preload, stiffness and bearing life is
exhibited. As the preload is increased, stiffness increases and the life of bearing decreases and
as the preload decreases, stiffness is reduced and the machine tool performance is
deteriorated. Vibration measurement serves as an effective tool for setting the preload during
the assembly processes. There is no need to have a theoretical model as the required
information can be obtain experimentally so that the method would not depend on the accuracy
of a model.

2. MODELING AND ANALYSIS

The ultimate aim of a finite element analysis is to recreate mathematically the behavior
of an actual engineering system. The spindle assembly was developed using beam and spring

elements. Figure 1 shows the finite element model of the Spindle assembly of a turning centre.

2
 Figure1 finite element model of the Spindle assembly

Table 2.1 Natural characteristics of the spindle assembly

Modal analysis is a process whereby

Natural we describe a structure in terms of

its natural characteristics, which are

Mode Frequency the frequency and mode shapes. It

can also serve as a starting point for
M
(HZ) another, more detailed, dynamic
analysis, such as transient analysis,
harmonic response analysis, or
spectrum analysis. The natural
frequencies and mode shapes are
important parameters in the design

1 587.9 of a structure for dynamic loading

conditions. The understanding and
visualization of mode shapes is
invaluable. It helps to identify areas
of weakness in the design or areas
where improvement is needed. The
development of a modal model is
useful for simulation and design
studies. Six mode shapes and the
natural frequency of the lathe are

2 590.3 tabulated in table 1.

Harmonic response analysis was used to determine the response of the system due to
harmonic load. Due to the presence of the rotating members in the structure, there exist

3
unbalanced forces, which vary harmonically. These unbalanced forces given by various
elements are in the structure was calculated and applied in the structure at the appropriate
locations.

The unbalanced forces is given by

F=m×r×ω 2

Where m= Mass of the element Kg

r= Eccentricity mm

= Angular velocity rad/s

The unbalanced forces for the spindle is calculated as follows

Weight of the spindle =r2L* Density

Volume =1.3383×106 mm3 , Density= 7.8×10-6

Weight of the spindle=102.3964 N

Calculation of Angular Velocity()

Speed of the spindle = 1200 rpm

=1200/60=20 Hz

Therefore = 2×20

=125.66 rad/s

According to the standards, the balanced quality grade for machine tool spindle is G 6.3mm/s
(vibration level V).

V =r

Eccentricity r =6.3/125.66

=0.05mm

Spindle unbalanced force = 8.241 N

Similarly, unbalanced forces due to front and rear bearings are 0.101 N and 0.0692 N.
Applying the unbalanced forces at respective points, the analysis was carried out considering
first ten modes and 3% damping. The response along horizontal and vertical direction was
determined at front and rear bearing housing are presented in table 2.

Table 2.2 Theoretical Vibration Velocities for Different Spindle Speeds

Sno Spindl Vibration Vibration Velocity

e Velocity at Front at Rear Bearing
Speed Bearing mm/s mm/s
RMS Horizon Vertic Horizont Vertic

4
 tal al al al
1 100 0.019 0.025 0.016 0.013
2 150 0.023 0.029 0.020 0.017
3 300 0.028 0.040 0.022 0.022
4 500 0.038 0.052 0.035 0.027
5 700 0.039 0.058 0.037 0.029
6 1200 0.072 0.075 0.052 0.050
7 1500 0.083 0.081 0.071 0.074

3.EXPERIMENTATION

Experiments were carried out on a cnc turning centre (GALAXY Midas O). The vibration
velocities was measured by using NI -PXI 1402Q and accelerometers. The accelerometers
ware fixed on the horizontal and vertical axis of the spindle at front and rear bearing housing.
Vibration velocity in mm/s at various spindle in non cutting condition are present in table 3. Lab
View 8.5 software was used to manipulate the extracted vibration signatures. The software
provide greater ease of use and faster performance for your data acquisition (DAQ) devices,
sound and vibration software provides a complete software solution for all audio, noise and
vibration, and machine condition monitoring applications. The LabVIEW Analysis VIs provide
additional LabVIEW functions for power spectra, frequency response functions (FRFs),
fractional-octave analysis, sound level measurements, order spectra, order maps, order
extraction, sensor calibration, human vibration filters, and torsional vibration.

PC IMPACT HAMMER KIT

NI PXI 1042 DAQ

LabVIEW Front Panel BNC CABLES

Fig 3.1 Experimentation Setup

5
 Figure 3.2 Power spectrum of the experimental model analysis

Table 3 Experimental Vibration Velocities for Different Spindle Speeds

Vibration Velocity Vibration Velocity

Spindl
at Front Bearing at Rear Bearing
e
Sno mm/s mm/s
Speed
RMS Horizont Vertica Horizonta Vertica
al l l l
0.0298
1 100 0.024 1 0.01846 0.01567
2 150 0.0251 0.0304 0.02231 0.01871
3 300 0.0304 0.0431 0.0243 0.02412
4 500 0.0401 0.0568 0.03874 0.02931
5 700 0.0405 0.0607 0.03875 0.0312
0.0771
6 1200 0.07423 6 0.05439 0.0521
0.0839
7 1500 0.08712 3 0.07968 0.0762

6
4. RESULT AND DISCUSSION

The results from the theoretical model analysis (Table2.1) and experimental model analysis
(Fig. 3.1) obtained were close, it was observed that theoretical values are less compared to the
experimental values. The results from the Structural analysis were shown with the experimental
results for various spindle speed in the table 2.2, it was absorbed that theoretical values
obtained were closely representing the vibration obtained from the experiments (table 3.2). It
was found that theoretical values were less than the experimental values, this may be due to un
balanced forces such as belt tension fluctuation, bearing defects and material defects which are
action during operation.

5. MAJOR REFERENCE

Claudiu F. Bisu, Philippe Darnis, Alain Gérard and Jean-Yves K’nevez. (2008) Displacements analysis

of self-excited vibrations in turning. Int J Adv Manuf Technol.

K N GUPTA (1997). Vibration - A tool for machine diagnostics and condition Monitoring. Sadhana, Vol.

22, Part 3, pp. 393-410.

M. Mahboubkhah, M. J. Nategh and S. Esmaeilzadeh Khadem. (2008). A comprehensive study on the

free vibration of machine tools’ hexapod table. Int J Adv Manuf Technol.

M.A. Mannan and B.J. Stone (1998). The use of vibratio measurement for quality controle of machine

tool spindle. Int J Adv Manuf Technol 14: 889-893.

Mohammed A. Alfares, Abdallah A and Elsharkawy (2003). Effects of axial preloading of angular

contact ball bearings on the dynamics of a grinding machine spindle system. Journal of Materials

Processing Technology 48–59.

Nobuaki Kamimoto, Yutaka Yamada, Masami Kitamura and Kiyoshi Nishikawa (2005) Evaluation of

vibration in many positions by SOM. Artif Life Robotics 9:7–11.

7
S. Saravanan, G.S. Yadava and P.V. Rao. (2006) Condition monitoring studies on spindle bearing of a

lathe. Int J Adv Manuf Technol 28: 993-1005.