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Technology Development and Future Challenge of Machine Tool Spindle

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Technology Development and Future Challenge of Machine Tool Spindle Technology development and future challenge of machine tool spindle Shinya Nakamura NSK Ltd., Japan E-mail: [email protected] [Received November 16, 2012; Accepted September 30, 2012] Abstract In this paper, the history for this 40 years of spindle speeding up and future technological challenge are described, at the same time, the latest spindle technology is introduced. Keywords: Machine tool spindle, Oil-air lubrication, 5-axis machine, Grease replenishing lubrication, Intelligent spindle 1 INTRODUCTION spectacularly in response with the cutting needs with the The machine tool spindles have been developed with a times. As the key technologies making progress of focus on high-speed technology as the reason behind that speeding up, the improvement of lubrication method such they aimed the improvement of cutting efficiency by the as grease lubrication, oil-air lubrication, and jet development of machining center on 1975 or later, in lubrication, the application of new material to bearings accordance with the demand of speeding up was (rolling elements , inner and outer rings and cage) such increased rapidly. as ceramic balls, and the advancement of design approach and technique of analysis are mentioned. After that the wide range of needs such as higher accuracy, higher stiffness, and improvement of reliability Figure 2 shows the investigation results of high-speed -1 etc. is come out. In addition, the needs in response to spindle (10000min over) displayed in Japan International environment, saving energy, 5-axis machine, multitasking Machine Tool Fair (JIMTOF) since 1982. In JIMTOF2010, machine and intelligent machine are come out. In this the progress of speeding up is standstill in recent years, article, the history of spindle speeding up and future and the maximum rotating speeds are focused on around -1 -1 technological challenge are described, at the same time, 12000min and 20000min . As the features of whole the latest spindle technology is introduced. machines, speaking of machining center, the exhibits of 5-axis machining center which has the turning mechanism of spindle(tool side) and table(work side) are increased, 2 SPEEDING UP OF SPINDLE and in the case that they are used as processing machine 2.1 History of spindle speeding up of aircraft components or dies, in order to attain high- efficiency process, high-speed spindle is equipped. In Figure 1 shows the history of spindle speeding up. The case of multitasking lathe, the trend toward speeding up dmn value of spindle bearing has been increased 400 NEDOair lubrication-in spindle ） -in spindle - ４350 Robust design bearing 10 Super lean lubrication Super lean oil Aircraft Preload shifting built -in spindle 300 Constant pressurebearing built components, （× High-speed Spinshot aluminum Ultrahigh-speed -air processing New ROBUSTcontact Oilball Series bearing angular High-stiffness High-speed 250 machining center Constant processingpressure built for die ROBUST Series angular contact ball bearing, (Jet lubrication) -air 200 Oil High-speed machining Cylindrical roller bearing Cylindrical roller bearing center Under race lubrication, Ceramic angular contact ball bearing angular contact ball Preload variable spindle -air lubrication) Built-in motor Neobrid (Oil ROBUST Series Bearing Machine processing 150 Automotive High-speed specification Grease replenishingNEW ROBUST system components etc. Small diameter ball Cylindrical roller bearing Ceramic ball bearing -air lubrication) (Grease lubrication) Hybrid(Oil cylindrical roller ROBUST Series angular Machining center bearing contact ball bearing 100 -air lubrication) (Grease lubrication) High-speed・ NC lathe (Oil angular contact ball NC milling machine Neobrid (Grease lubrication) High-stiffness Hybrid angular contact ball bearing bearing valueof main spindle bearing NC lathe Lathe Milling machine Hybrid angular contact ball bearing n (Grease lubrication) m 50 Angular contact ball bearing d Tapered roller bearing Cylindrical roller bearing (Grease lubrication) (Forced-circulation oiling) Development era 1970 75 80 85 90 94 98 2002 2006 2010 Figure 1: Transition of speeding up of machine tool spindles © Journal of SME-Japan of milling spindle is remarkable. heat generation value, more specifically, against the The so-called built-in motor spindle which the driving thermal disturbance, the bearing has a characteristic of motor is integrated inside the spindle is become regular thermal insensitivity). For these high-speed spindles, to use as it is indispensable technology for high-speed respond the demands described above, the ultrahigh- spindle, for the attainment of ultrahigh-speed rotation, speed bearings “ROBUST Series”, which bearing internal 1) further speeding up, high output, and downsizing of the design was optimized as described below are adopted . rotor and stator are expected. Recently in response to (Refer to Figure 3) environment and saving energy, additional speeding up Under the processing conditions with various cutting and improvement of reliability of grease lubrication begin conditions and rotational fluctuation, the temperature to be required. change inside the spindle is significant and the temperature difference between inner and outer rings involved, it causes the decrease of bearing internal 2.2 High-speed bearing technology 2.2 High-speed bearing technology clearance, the contact angles between balls and raceway As for the high-speed spindle of recent machine tool, in groove of inner and outer rings change rapidly, and the order to make the inertia of rotating parts, the adoption of internal preload of bearing increases, the PV value (P: built-in motor spindle which integrates compact and high Contact surface pressure, V: Sliding speed) of rolling output rotor is increasing. However, in case of such contact area between the raceway groove of inner and spindle structure, at the transition period of rapid outer rings and balls increases. The internal specification rotational fluctuation, ambient environmental variation of ROBUST Series bearings is that the change of PV (heat generation change of motor and outer cylinder value is minimized under the conditions described above cooling) becomes significant, and the bearing of spindle is on the basis of analytical results by the computer as the exposed under the harsh thermal fluctuation condition. affectors such as ball diameter, raceway groove curvature For the spindle bearing, it is the most important to have of inner and outer rings, and contact angle etc. are the characteristics of seizure resistance under such considered the parameters. And the application of special environmental condition, and it is necessary to have carbonitrided steel (SHX steel) and the adoption of high- temperature robust performance (against thermal load strength plastic cage of special configuration that has fluctuation, the bearing itself shows small fluctuation of Grease replenishing Grease replenishing Cylindrical roller Angular contact ball bearing Technologies for speeding up bearing Double-row cylindrical roller Machine processing bearing with TB cage Shaft center cooling (Drill, Milling processing) Automotive components etc. ROBUST Series Built-in spindle 70 Neobrid angular Preload adjustable spindle contact Lathe milling shaft60 Hybrid cylindrical Ball guided plastic cage 50 roller bearing TY type Ceramic roller High-speed40 processing for die Hybrid angular 30 Oil-air lubrication Ceramic ball Aircraft 20 components Small diameter ball High-speed 10 BNC Series aluminum 0 processing 25th (2010) 10 24th (2008) 13 23th (2006) 15 22th (2004) 18 21th (2002) 22 20th (2000) 25 28 19th (1998) SPEED 18th (1996) 35 17th (1994) 40 x1000min-1 16th (1992) 60 15th (1990) 100 14th (1988) Internal grinding process 13th (1986) 12th (1984) 11th (1982) Figure 2: JIMTOF High-speed spindle display situation (10000min-1 over)Investigated by NSK Ultrahigh-speed angular contact ball bearing Spinshot II bearing Ultrahigh-speed single-row cylindrical roller bearing Figure 3 : Examples of various ROBUST Series © Journal of SME-Japan excellent heat resistance and wear resistance improve seizure resistance additionally. Also, the Spinshot bearings that the lubricating oil is replenished effectively under the condition of high-speed operation by optimizing the bearing configuration are developed. 3 TECHNICAL CHALLENGE OF SPINDLE Figure 4 shows the technologies required from the machine tools in Japan in the future. To begin with, the technologies required from the machine tools, secondly Figure 5: Conventional oil-air Figure 6: Spinshot system the technologies required from the spindle and the system bearings were summarized. Until recently the development of high speed, high accuracy, and high stiffness was focused but recently the durability and the improvement of reliability are required, especially in the past several years, the environmental responsiveness, Centrifugal force saving energy, and advanced grease lubrication for Air flow maintenance-free operation are required. And the Surface tension requirement of Intelligent and Smart by applying the Oil droplet sensor is increasing. Technological needs Needs required from Needs required from bearing required from machine main spindle Air pressure is Flaking point of Processing Improvement of Speeding up and high reducedreduced byby groovegroove of die processed Improvement of accuracy as accuracy level of oil droplet surface quality bearing self-inclusively on the circumference main spindle Processing Improvement of Bearing improved
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