This project seeks to develop comprehensive dynamic and thermal models for high speed spindle systems. The study addresses the dynamic characteristics of high speed spindle-bearing systems during operation, including the effects of bearing initial set-up and geometry, initial preloads, thermal load, external cutting force, rotational speed, and bearing spacing, and attempts to develop models to predict dynamic compliance and thermal stability. In addition, advanced bearing designs and materials will be tested and analyzed, and their performance will be evaluated in comparison with conventional bearings. As a final outcome of the project, a computer aided analysis system for high speed spindles will be developed. This analysis package will provide prediction of spindle-bearing dynamic characteristics, bearing contact loads and temperature rise, which can lead to optimal design and operation of high speed spindles. Successful analysis and design of high speed spindles will enable easier implementation of high speed machining. Spindle failure is currently a significant problem in high speed machining practice.
