Design Parameter Sensitivity Analysis of High-Speed Motorized Spindle Systems Considering High-Speed Effects

With increasing demands for higher productivity and lower production costs, high-speed machine tools have been widely utilized in the modern production facilities. Meanwhile, to meet the requirements of higher spindle speeds and more versatile machining capabilities, it is becoming necessary for engineers to thoroughly realize how the spindle system design would influence the system dynamics with considering highspeed effects. With this understanding, machine tool designers can enhance the performances of automatic high-speed machine tools such as spindle speeds, metal removal rates, and machining quality. In this paper, I first develop a design flow chart to represent the overall spindle design problems. Based on this flow chart, eight design parameters are identified. A design sensitivity analysis of these eight design parameters is then conducted based on an integrated finite element method model to investigate their influence on the natural frequencies of the spindle system. The results show that the most important design parameters to the system dynamics include spacing between the front and rear bearing sets, spacing between middle line of the two bearing set and the free end of cutter, and length of the spindle shaft.