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Influence of Unbalanced Electromagnetic Force and Air Supply Pressure Fluctuation in Air Bearing Spindles on Machining Surface Topography

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International Journal of Precision Engineering and Manufacturing Aims and scope Submit manuscript

Abstract

Air bearing spindles (ABS) can meet high accuracy demands for the precise rotation motion, which adopt air bearings to support spindle shaft, and the spindle shaft directly connects the motor rotor. The unbalanced electromagnetic force caused by motor rotor eccentricity (MRE) and air pressure fluctuation (APF) are two important influential factors to the dynamic performance of the spindle system and machining surface quality. This paper addresses the problems of measuring the MRE and APF in an ABS through testing machining surface topography. A permanent magnet synchronous motor (PMSM) was modelled by finite element simulation (FES). Through FES it found that the MRE between the motor rotor and stator hole produced a radial magnetic force (RMF), which could cause ABS to periodically vibrate in the axial direction. Besides, the change of the air supply caused the stiffness variation of ABS and result in the tilt error motions of the spindle shaft. A theoretical model of machining surface topography considering MRE and APF was then proposed for the first time, which revealed that the MRE and APF resulted in the periodic fluctuations of the machining surface topography. The overall surface topography then became grooved surfaces. The above findings were finally validated by measurement results of ultraprecision diamond turning experiments.

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Abbreviations

ABS:

Air bearing spindles

PMSM:

Permanent magnet synchronous motor

MRE:

Motor rotor eccentricity

RMF:

Radial magnetic force

APF:

Air pressure variation

FES:

Finite element simulation

M :

Centroid

n :

Rotational speed

t :

Turning time

f :

Feed rate

ω :

The vibration frequency

∆L :

Amplitude of the vibration

k :

Coefficient

P s :

Air supply pressure

P a :

Atmospheric pressure, 0.1 MPa

T :

Temperature

d 1 :

Orifice diameter

h 2 :

Air gap

Q 1 :

Flow rate

V :

Volume

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Acknowledgements

The authors gratefully acknowledge financial support of the International Science & Technology Cooperation Program of China (No. 2015DFA70630), the National Natural Science Foundation of China (Grant Nos. 51505107 and 51705462), and Zhejiang Provincial Natural Science Foundation of China (Grant No. LQ20E050021).

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Authors and Affiliations

  1. School of Mechatronics Engineering, Harbin Institute of Technology, Harbin, 150001, China

    Yazhou Sun, Quanhui Wu & Wanqun Chen

  2. Key Laboratory of E&M, Ministry of Education & Zhejiang Province, Zhejiang University of Technology, Hangzhou, 310032, China

    Quanhui Wu & Guoda Chen

  3. Centre for Precision Manufacturing, DMEM, University of Strathclyde, Glasgow, G1 1XJ, UK

    Xichun Luo

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  1. Yazhou Sun
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Correspondence to Quanhui Wu.

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Sun, Y., Wu, Q., Chen, W. et al. Influence of Unbalanced Electromagnetic Force and Air Supply Pressure Fluctuation in Air Bearing Spindles on Machining Surface Topography. Int. J. Precis. Eng. Manuf. 22, 1–12 (2021). https://doi.org/10.1007/s12541-020-00428-3

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