• 한국결정성장학회지
• /
• 제16권6호
• /
• pp.273-277
• /
• 2006

High velocity of oxy-fuel (HVOF) thermal spray coating is progressively replacing the other classical hard coatings such as chrome plating and ceramic coating by the classical methods, since the very toxic $Cr^{6+}$ ion is well known as carcinogen causing lung cancer, and the ceramic coatings are brittle. Co-alloy T800 powder is coated on the Inconel 718 substrates by the HVOF coating procesess developed by this laboratory. For the study of the possibility of replacing of chrome plating, the wear properties of HVOF Co-alloy T800 coatings are investigated using the reciprocating sliding tester with a counter sliding SUS 304 ball both at room and at an elevated temperature of $1000^{\circ}F\;(538^{\circ}C)$. The possibility as durability improvement coating is studied for the application to the high speed spindles vulnerable to frictional heat and wear. Wear mechanisms at the reciprocating sliding wear test are studied far the application to the systems similar to the sliding test such as high speed spindles. Wear debris and frictional coefficients of T800 coatings both at room and at an elevated temperature of $538^{\circ}C$ are drastically reduced compared to those of non-coated surface of Inconel 718 substrates. Wear traces and friction coefficients of both coated and non-coated surfaces are drastically reduced at a high temperature of $538^{\circ}C$ compared with those at room temperature. These show that the coating is highly recommendable far the durability Improvement coating on the surfaces vulnerable to frictional heat and wear.

• 한국정밀공학회:학술대회논문집
• /
• 한국정밀공학회 2004년도 추계학술대회 논문집
• /
• pp.788-791
• /
• 2004

This paper presents a general description of single and dual contact tooling systems, finite element analysis, and discussions on the application of the system to the 5-head router machine which is in particular for aerospace components. This study has been performed as part of the development of the new generation 5-head router machine which is designed for high productivity. Such high productivity in essence requires high speed rotation and multiple spindles in one machine. The high speed rotation may exceed a range in a conventional single contact tooling system. The conventional tooling system is reevaluated in comparison with the dual-contact system. Finite element analysis using simplified spindle models compares major differences in the two systems. Some problems in the application to the 5-head router machine are discussed.

• International Journal of Precision Engineering and Manufacturing
• /
• 제7권3호
• /
• pp.3-7
• /
• 2006

For the purpose to improve and to automate designing of high-speed spindle units (SU's), we have developed the mathematical models and software to estimate SU performance characteristics, including the run-out of spindles running on ball bearings. In order to understand better the mechanics of high-speed SUs, the dynamic interaction of ball bearings and SU, and the influence of the bearing imperfections and SU's operational conditions on the run-out, we have carried out computer simulation and experimental studies. Through the study of SU's, we have found out that run-out of SU can vary drastically with variation of rpm. The influences of rotation speed and of accuracy parameters of bearings on the SU accuracy have the greatest importance. The influence of bearing preload has a secondary importance. Comparison of the results of these studies has demonstrated adequacy of the models and software developed to the real SU's.

• 한국공작기계학회:학술대회논문집
• /
• 한국공작기계학회 2005년도 춘계학술대회 논문집
• /
• pp.138-143
• /
• 2005

The important problem in the high speed spindles is to reduce and minimize the thermal effect by the motor and ball bearings. Thermal characteristics according to the bearing preload and hollow shaft cooling are studied for the spindle with the oil mist lubrication and high frequency motor. Temperature distribution and thermal deformation according to the spindle speed, preload and flow rate are measured by thermocouple and gap sensor. Temperature distribution and thermal deformation are analyzed by using the finite element method. The results of analysis are compared with the measured data. This paper show that the suitable preload and hollow shaft cooling are very effective to minimize the thermal effect by the motor and ball bearings. This study indicates that temperature distribution and thermal deformation of the high speed spindle system can be estimated reasonably by using the three dimensional model through the finite element method and supports thermal optimization and more effective cooling method.

• 한국공작기계학회:학술대회논문집
• /
• 한국공작기계학회 2004년도 춘계학술대회 논문집
• /
• pp.404-409
• /
• 2004

To maximize the productivity in machining molds and dies, machine tools should operate at high speeds. During the high speed operation of moving frames or spindles, vibration problems are apt to occur if the machine tool structures are made of conventional steel materials with inferior damping characteristics. However, self-excited vibration or chatter is bound to occur during high speed machining when cutting speed exceeds the stability limit of machine tool. Chatter is undesirable because of its adverse effect on surface finish, machining accuracy, and tool life. Furthermore, chatter is a major cause of reducing production rate because, if no remedy can be found, metal removal rates have to be lowered until vibration-free performances is obtained. Also, the resonant vibration of machine tools frequently occurs when operating frequency approaches one of their natural frequencies because machine tools have several natural frequencies due to their many continuous structural elements. However, these vibration problems are closely related to damping characteristics of machine tool structures. The polymer concrete has high potential for machine tool bed due to its good damping characteristics with moderate stiffness. This paper presents the use of polymer concrete and sandwich structures to overcome vibration problems. Also, co-cure bonding method for functional part mounting was exhibited experimentally, by which manufacturing time and cost for polymer concrete bed will be remarkably reduced.

• 한국기계가공학회지
• /
• 제11권2호
• /
• pp.152-158
• /
• 2012

A newly developed attachment type high-speed spindle can be easily attached to the conventional CNC machining center to allow high-speed machining with low investment costs. This study has focused on the application of a conventional CNC machining center equipped with an attachment type high-speed spindle. A specimen of plastic mold material has been machined to compare the cutting effectiveness of the high-speed machining center and the conventional machining center with the attachment type high-speed spindle respectively. The rotational accuracy of the spindles are measured by a transmission optic measurement system and the surface roughness of the workpiece in accordance with revolution speed(rpm) of the spindle are investigated respectively. As the experimental results, it was shown that the surface roughness of the machined workpiece was $3.42{\mu}mR_{max}$, $0.46{\mu}mR_a$ in the case of attachment type spindle and $1.81{\mu}mR_{max}$, $0.275{\mu}mR_a$ in the case of the high-speed machining center. Moreover, the mean rotational accuracy was $7.57{\mu}m$ in the case of the attachment type spindle and $7.39{\mu}m$ in the case of the high-speed machining center.

• 한국정밀공학회지
• /
• 제31권8호
• /
• pp.677-682
• /
• 2014

One of the most important element technologies for achieving high-precision in machine tool spindle systems is preload technology for the bearing of spindle systems. Fixed position preload, constant pressure preload, conversion preload and variable preload methods have been applied for the spindle systems. In this study, a new variable preload method using centrifugal force and rubber pressure is used for reducing installation costs through simplifying its structure. The main objective of the work is the verification of the operability in a preload device using the rubber pressure by the finite element analysis. It is shown that the variable preload device proposed in this study is applicable to high speed machine tool spindles.

• 한국소음진동공학회논문집
• /
• 제19권11호
• /
• pp.1214-1221
• /
• 2009

A high-speed spindle can be very sensitive to rotating mass unbalance which has harmful effect on many machine tools. Therefore, the balancing procedure to reduce vibration in rotating system is certainly needed for all high-speed spindles. So, balancing procedure was performed with a spindle-bearing system for CNC automatic lathe by using numerical procedure. The spindle is supported by the angular contact ball bearings and the motor rotor is fixed at the middle of spindle. The spindle-bearing system has been investigated using combined methodologies of finite elements and transfer matrices. The balancing was performed through influence coefficient method and the comparison was made by whirl responses between before balancing and after balancing. As a result, balancing of simple spindle model reduced whirl orbit magnitude in case of a completely assembled spindle model.

• 한국정밀공학회:학술대회논문집
• /
• 한국정밀공학회 1996년도 춘계학술대회 논문집
• /
• pp.651-657
• /
• 1996

Industrial products are getting more and more complex. The number of parts or components and the variety of manufacturing processes are increasing. This leads to rapid product oriented machine tools. The process integrated CNC lathe is one of the these machine tools which can produce numerous parts and various machining processes and reduce the lead time and non-machining time. Therefore this study deals with the design technique of a process-intergated CNC lathe which can reduce the tact time and production cost by the speed-up of the tooling system and the high-speed machining oriented construction of 2 spindles and 2 turrets.

• 한국생산제조학회지
• /
• 제20권6호
• /
• pp.685-691
• /
• 2011

The Bearing preload units are used for stable rotational movements of high speed spindles. The feeding mechanism of the preload unit is important to prevent overheat of bearings and to keep constant bearing load under thermal deformation of spindle unit. In this study, ball slide guide and ball bush as feeding mechanism of preload unit are selected. The maximum static friction force, radial stiffness and damping ratio of ball slide guide with ball load, ball number and ball size are widely investigated. In conclusion, the surface of ball slide guide must be heat treated to reduce static friction force. The number and size of ball are increased to control sensitive bearing preload force.