ADAPTIVE COOLING AND

SPINDLE CONDITION
MONITORING SYSTEM

Guided by:

Dr. B. Giriraj A.P. Arun

Senior lecturer R. No. 07MI31
Department of Mechanical ME CIM
Engineering
 LITERATURE SURVEY

REAL TIME SPINDLE HEALTH MONITORING

“Design of a Real-time Spindle Health Monitoring and Diagnosis System

Based on Open Systems Architecture “ by Li Zhang [6]. This paper presents a
software design for an automated spindle health monitoring system. An analytic
wavelet based envelope spectrum algorithm is proposed and coded in software for
effective and efficient spindle degradation identification, defect localization, and
damage growth tracking

“Modal Parameter Identification from Output-only Measurement Data:

Application to Operating Spindle Condition Monitoring “ by Robert Gao et al. This
paper presents an experimental investigation of the dynamics of a custom-
designed spindle test system under different operation conditions and at various
stages of its service life. The obtained modal parameters provide insight into
structural changes of the spindle during its service life, and can be used as
indicators for enhanced spindle condition monitoring.
 Lit. survey cont…
“Thermal Error Measurement and Real Time Compensation System for
the CNC Machine Tools Incorporating the Spindle Thermal Error and the Feed Axis
Thermal Error” by Pahk et al [2]. In this paper, the thermal spindle error and
thermal feed axis error have been considered, and a measurement/compensation
system for thermal error is introduced. In order to compensate for the thermal error
in real-time, the coordinates of the CNC controller are modified in the PMC
program. After real-time compensation, the machine tool accuracy improved about
4–5 times

LUBRICATION OF SPINDLE

“ A parametric study on oil/air lubrication of a high-speed spindle” by Yu-

Tai Kung et al [9]. In this study, the performance of a high-speed spindle under
different lubrication parameters and preloads was investigated. The Taguchi
method was applied to study the effects of design parameters on the lubrication
efficiency. This method can also be used to obtain the optimum lubrication
conditions. The optimum operating conditions that create the smallest temperature
increase were established. The effects of preload on the temperature increase, the
thermal deformation and the static stiffness of an oil/air lubricated spindle were
studied. The results provide a useful tool in designing a high-speed spindle with a
small increase in temperature and sufficient static stiffness.
 Lit. survey cont…
SPINDLE THERMAL DISPLACEMENT

“The building of spindle thermal displacement model of high speed

machine center” by Zone-Ching Lin et al [1]. This article mainly analyzes the
issues of spindle thermal displacement upon the acceleration of spindle, and
proposes a complex multivariable regression analytical method to build a
spindle thermal displacement model, so as to predict the thermal displacement
of spindle. The machining precision can effectively be improved after the
compensation of its spindle thermal displacement model.

“Spindle Housing Design Parameter Optimization Considering Thermo-

Elastic Behavior” by Kim et al[3]. This paper presents a simulation method for
predicting thermo-elastic behaviors of spindle-bearing system and an
optimization procedure for housing design parameters in relation to various
spindle-bearing operating and surrounding conditions such as assembling
tolerance, geometric dimension, cooling condition and thermal deformation. this
paper shows a numerical example of formulation and optimization results for
spindle housing design parameters
 Lit. survey cont…
BEARING EFFECTS ON SPINDLE

“Analysis of bearing configuration effects on high speed spindles using an

integrated dynamic thermo-mechanical spindle model” by Yung et al[7]. This work
presents the effects of bearing configuration on the thermo-dynamic behavior of high
speed spindles. It is shown that bearing orientation has a significant effect on spindle
stiffness. Finally, the effects of various bearing configurations on spindle thermal and
dynamic behavior are illustrated through numerical analysis with three different spindles.

“Effect of Bearing Surroundings on the High-Speed Spindle-Bearing

Compliance” by. Kim et al [4]. This paper investigates the effect of bearing assembly
tolerance on spindle-bearing compliance in a high-speed spindle system. analytical and
experimental investigations of the bearing compliance are conducted with consideration
of both the elastic deformation of the race and the thermal deformation of the housing in
terms of the bearing stiffness. The experimental results show the effectiveness of the
proposed equations, which are simple and useful for fast calculation of the bearing
stiffness by dynamic simulation.
 OBJECTI
VE
The objective of this project is

 To design and develop a spindle health

monitoring system for efficient spindle degradation
identification

 To design and develop a adaptive spindle

cooling system using virtual instrumentation
software for minimizing thermal distortion
 NEED OF THE CURRENT STUDY
High-speed cutting technology is now used increasingly in
a broad range of applications to machine ferrous metals and
nonmetallic materials. A high-speed and high-power motorized
spindle may be the most important part among the key
technologies of the high speed cutting. Both the spindle speed
and spindle power are required to be increased for future
applications.

When power and speed increase, the spindle thermal

growth also becomes more important. Cutting-edge technology for
a spindle design strongly requires a high rotating speed and a low
thermal deformation of the spindle system, because the spindle
for a machine tool must be sufficiently stiff to minimize axial and
radial displacement according to the external force.
 PROBLEM DEFINITION
A premature failure of machine tool spindle bearings is a major problem
in production and can result in enormous loss in the production and spindle
rehabilitation cost [6].

Unexpected failure of machine tools can cause severe part damage

and costly machine down time, affecting the overall productivity as well as
maintenance cost. Since spindles are essential elements in virtually all machine
tools and their working condition directly reflects upon machine tool
performance.

Even though a cooling jacket is included in the assembly to remove the

generated heat of the built in motor and bearings, a large spindle thermal
growth was still found. Some times during continuous running of cooler 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
but it is now felt that thermal stability has to be considered as a fundamental
part of the accuracy requirements.
 FEASIBILITY ANALYSIS
Machine Specification

Machine: 3-axis Vertical CNC milling

Power: 5KW
Speed: Integrated motorized spindle that can rotate up to 40,000 rpm.
Work Piece: Aluminum alloy of LM6 grade.
Tool: two-flute titanium aluminum nitride coated solid carbide square end mill.
Tool Specification

Diameter: 6mm
Helix angle: 30°
Radial rake angle: 20°

Work Piece Material

The workpiece material selected for experimental

purpose is aluminium LM6 (grade 6550) as per specification given in table
SENSORS USED

Thermocouple ( J type)
Acoustic emission sensor
Accelerometer

FLOW CONTROL VALVE

Solenoid operated Proportional flow control valve

SOFTWARE USED

LabVIEW 8.2
 SCOPE OF THE PROJECT

The design is functionally adaptive and

presents a new tool that enables more effective and
efficient monitoring and diagnosis of machine spindles, and
contributes directly to the development of a new generation
of smart machine tools. In addition to spindles, the
software can be applied to the health diagnosis of other
types of machines.
 METHODOLOGY
 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 , flow rate is to be altered using real time adaptive cooling system to
maintain spindle temperature to achieve better dimensional accuracy .

 The LabVIEW program will be used to receive temperature from thermocouple and using
a feedback control, flow rate is to be controlled.

 In order to establish an adaptive cooling system the flow control valve, is 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 will be controlled automatically
to maintain the flow rate

 To monitor the vibration and acoustic emission, respective sensors were to be

mounted over the spindle. Sensors are to be interface through the input port of
the Data Acquisition Card (DAQ).

 Output from the sensors will be acquired from DAQ through Analog input

 If the parameters were found to be abnormal warning signal will be given to the
worker and spindle will be stopped
COOLANT IN HOSE

COOLANT OUT

COOLER

TEMP SENSOR
FLOW CONTROL
VALVE

LabVIEW

DAQ

ADAPTIVE COOLING SYSTEM

METHODOLOGY – ADAPTIVE COOLING SYSTEM
SPINDLE CONDITION MONITORING SYSTEM
VERTICAL
MACHINING
CENTER
SPINDLE

SENSORS Temp sensor

Acoustic
emission
sensor
DATA Vibration
ACQUISITION sensor

V I SOFTWARE

CONDITION
MONITORING
(Human
Machine
Interface)
CONDITION MONITORING
 EXPERIMENTAL INVESTIGATION
MEASUREMENT OF TEMPERATURE PROFILE

The temperature rise was measured at the outer race of front bearing, tool holder
tip, spindle nose and stator with aid of thermocouple and Infra-Red sensor. Holes were
provided to measure the temperature at the outer race of front bearing and stator. The
measured temperature rise on no load at different operating speeds is shown in table

TEMPERATURE IN 0 C
SPEED FRONT BEARING STATOR SPINDLE NOSE TOOL
(rpm) OUTER RACE HOLDER
TIP

5000 34 33 33.4 33
10000 37.7 37 36.4 34.9
15000 39.5 41.4 38.4 35.3
20000 45.0 44.7 41 36.4
25000 51.0 47.8 43.3 37.8
30000 54.9 60.8 47.2 39.5
35000 58.0 65.6 48.5 41.8
40000 65.0 72.5 51.2 44.5
 The thermal deformation of spindle tool holder tip was measured with aid of
micrometer dial gauge. Table shows the measured axial and radial deformations of
the spindle tool holder tip at different operating speeds. The maximum spindle tool
holder tip deflection in radial direction is 3µm at 40000 rpm in free rotating condition.
The axial deflection varies from 3µm to 16µm for a speed range of 5000 rpm to 40000
rpm.

SPEED DEFORMATIONS(µm)
(rpm) AXIAL RADIAL
3 -
5000
6 -
10000
7 1
15000
8 1
20000
9 2
25000
11 2
30000
13 3
35000
16 3
40000
 INFLUENCE OF THERMAL DEFORMATION ON
DIMENSIONAL ACCURACY

The following procedure has been followed to quantify the thermal error :

The process parameters were first fixed for the given tool (6mm diameter
carbide tipped end mill) and workpiece material (65540 grade aluminium).
Experiments were conducted at spindle speed of 20000 rpm with a feed rate of
300mm/min and 2mm depth of cut.

The CNC control was switched on and the work datum was set with
reference to the workpiece. A simple program was written for machining a slot in the
workpiece
 Then the spindle was operated at a constant speed and a slot was machined
(with the cooling ON and the oil circulating at room temperature).

Then the spindle was moved out of work piece and made to rotate for 30 min.
so as to increase the system temperature.

The second slot was made nearer to the first slot, keeping the depth of cut,
feed and cutting speed constant.

The above process was repeated for two more times with 30 min. interval.

Then the outlet oil temperature of chiller unit was reduced to 200 C and final slot
was taken.

The dimensional accuracy of workpiece is to be found so as to determine the

influence of spindle thermal deformation.
 Machined workpiece

FURTHER WORK :

Further work in this project is to implement the flow control valve and again
experimental investigation has to be carried out for finding the improvement

Then AE sensor and vibration sensor have to be mounted for the purpose of
monitoring the spindle condition.
 MAJOR REFERENCES

1, Zone-Ching Lin . Jia-Shing Chang, 2007, “The building of spindle thermal displacement model of
high speed machine center”, International Journal of Advanced Manufacturing Technology, Vol.34, pp. 556–566

2, H. J. Pahk and S. W. Lee, 2002, “Thermal Error Measurement and Real Time Compensation
System for the CNC Machine Tools Incorporating the Spindle Thermal Error and the Feed Axis Thermal Error”,
International Journal of Advanced Manufacturing Technology , Vol.20, pp.487–494

3, S.-M. Kim · S.-K. Lee, 2005, “Spindle Housing Design Parameter Optimization Considering
Thermo-Elastic Behavior”, International Journal of Advanced Manufacturing Technology, Vol.25, pp.1061–1070

4, S.-M. Kim, S.-K. Lee and K.-J. Lee, 2002, “ Effect of Bearing Surroundings on the High-Speed
Spindle-Bearing Compliance”, International Journal of Advanced Manufacturing Technology, Vol.19, pp.551–
557

5, Jenq-Shyong Chen , Wei-Yao Hsu, 2003, ” Characterizations and models for the thermal growth of
a motorized high speed spindle”, International Journal of Machine Tools & Manufacture, Vol.43, pp.1163–1170

6, Li Zhang, Ruqiang Yan, 2007, “ Design of a Real-time Spindle Health Monitoring and Diagnosis
System Based on Open Systems Architecture”, International Smart Machining Systems, 2007, vol.19, pp.342-
348

7, Hongqi Li, Yung C. Shin, 2004, “Analysis of bearing configuration effects on high speed spindles
using an integrated dynamic thermo-mechanical spindle model, International Journal of Machine Tools &
Manufacture, Vol.44, pp.347–364

8, Hayato YOSHIOKA, shimpei MATSUMURA, 2006, “ Minimising thermal deformation of aerostatic

 9, V Prabhu Raja, J Kanchana, K Ramachandra, P Radhakrishnan., 2002, “Prediction of Thermal
Deflection at Spindle Nose-tool Holder Interface in HSM”, international ansys conference proceedings.

10, Cheng-Hsien Wu, Yu-Tai Kung, 2005, “ A parametric study on oil/air lubrication of a high-speed
spindle”, Precision Engineering, Vol.29, pp.162–167

11, Ruqiang Yan and Robert X. Gao, 2008,” Modal Parameter Identification from Output-only
Measurement Data: Application to Operating Spindle Condition Monitoring”, Proceedings of the 8th Internationa
Conference on Frontiers of Design and Manufacturing. Tianjin, China.

12, www.machinerylubrication.com

13, www.ahrinternational.com/bearing_materials_table.com

14, www.yampanet.com/Technology/technology.htm

15, www.controlres.com/adaptive_cooling.htm

16, Precision Engineering Manufacturing by R.L.Moorthy

TIME LINE ACTIVITIES
 THANK
YOU
 ** Commercial equipment and software, many of which are either
registered or trademarked, are identified in order to adequately specify certain
procedures. In no case does such identification imply recommendation or
endorsement by the National Institute of Standards and Technology, nor does it
imply that the materials or equipment identified are necessarily the best available
for the purpose.