Dynamic Thermal-Structure Coupling Analysis and Experimental Study on Ball Screw Feed Drive System of Precision Machine Tools

Abstract:

To improve the simulation accuracy of the thermal characteristic of ball screw feed drive systems, a dynamic thermal-structure coupling model, which considered the effect of the thermal contact conductance (TCC) of the solid joint on the accuracy of simulation results, was proposed to conduct thermal characteristic analysis of ball screw feed drive systems. The predictive model for TCC was proposed based on the micro morphology description of rough surfaces and the contact load distribution of solid joints. Then, the dynamic thermal-structure model of the ball screw feed drive system was established. To validate the effectiveness of the dynamic thermal-structure coupling model, thermal characteristic experiments of the ball screw feed drive system were conducted under different feed rates. The results showed that the simulation accuracy of temperature field and axial thermal elongation can be improved from 65% to 87% and from 70% to 85%, respectively.

• Periodical: Applied Mechanics and Materials (Volume 868)
• Pages: 124-135
• DOI: https://doi.org/10.4028/www.scientific.net/AMM.868.124
• Online since: July 2017
• Authors: Chi Ma*, Jun Yang, Xue Song Mei, Liang Zhao, Hu Shi, Dong Sheng Zhang
• Keywords: Ball Screw Feed Drive System, Finite Element Analysis, Temperature Field Distribution, Thermal Contact Conductance, Thermal Deformation Variation

References

[1] Bryan J. International status of thermal error research (1990) [J]. CIRP annals-manufacturing technology, 1990, 39 (2): 645-656.

DOI: 10.1016/s0007-8506(07)63001-7

[2] Mayr J, Jedrzejewski J, Uhlmann E, et al. Thermal issues in machine tools [J]. CIRP Annals-Manufacturing Technology, 2012, 61(2): 771-791.

DOI: 10.1016/j.cirp.2012.05.008

[3] Altintas Y, Verl A, Brecher C, et al. Machine tool feed drives [J]. CIRP Annals-Manufacturing Technology, 2011, 60(2): 779-796.

DOI: 10.1016/j.cirp.2011.05.010

[4] Li Y, Zhao W, Lan S, et al. A review on spindle thermal error compensation in machine tools [J]. International Journal of Machine Tools and Manufacture, 2015, 95: 20-38.

DOI: 10.1016/j.ijmachtools.2015.04.008

[5] Huang S C. Analysis of a model to forecast thermal deformation of ball screw feed drive systems [J]. International Journal of Machine tools and manufacture, 1995, 35 (8): 1099-1104.

DOI: 10.1016/0890-6955(95)90404-a

[6] Shi H, Ma C, Yang J, et al. Investigation into effect of thermal expansion on thermally induced error of ball screw feed drive system of precision machine tools [J]. International Journal of Machine Tools and Manufacture, (2015).

DOI: 10.1016/j.ijmachtools.2015.07.003

[7] Yun W S, Kim S K, Cho D W. Thermal error analysis for a CNC lathe feed drive system [J]. International Journal of Machine tools and manufacture, 1999, 39 (7): 1087-1101.

DOI: 10.1016/s0890-6955(98)00073-x

[8] Pahk H, Lee S W. Thermal error measurement and real time compensation system for the CNC machine tools incorporating the spindle thermal error and the feed axis thermal error [J]. The International Journal of Advanced Manufacturing Technology, 2002, 20(7): 487-494.

DOI: 10.1007/s001700200182

[9] Min X, Jiang S. A thermal model of a ball screw feed drive system for a machine tool [J]. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, 2011, 225 (1): 186-193.

DOI: 10.1177/09544062jmes2148

[10] Wu C H, Kung Y T. Thermal analysis for the feed drive system of a CNC machine center [J]. International Journal of machine tools and manufacture, 2003, 43 (15): 1521-1528.

DOI: 10.1016/j.ijmachtools.2003.08.008

[11] Uhlmann E, Hu J. Thermal modelling of an HSC machining centre to predict thermal error of the feed system [J]. Production Engineering, 2012, 6 (6): 603-610.

DOI: 10.1007/s11740-012-0406-6

[12] Yang J, Zhang D, Mei X, et al. Thermal error simulation and compensation in a jig-boring machine equipped with a dual-drive servo feed system [J]. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2015, 229 (1 suppl): 43-63.

DOI: 10.1177/0954405414555592

[13] Ma C, Mei X, Yang J, et al. Thermal characteristics analysis and experimental study on the high-speed spindle system[J]. The International Journal of Advanced Manufacturing Technology, 2015, 79(1-4): 469-489.

DOI: 10.1007/s00170-015-6821-z

[14] Ma C, Yang J, Zhao L, et al. Simulation and experimental study on the thermally induced deformations of high-speed spindle system [J]. Applied Thermal Engineering, 2015, 86: 251-268.

DOI: 10.1016/j.applthermaleng.2015.04.064

[15] Ma C, Zhao L, Shi H, et al. Experimental and simulation study on the thermal characteristics of the high-speed spindle system[J]. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, 2017, 231(6): 1072-1093.

DOI: 10.1177/0954406216631573

[16] Lin M C, Ravani B, Velinsky S A. Kinematics of the ball screw mechanism [J]. Journal of mechanical design, 1994, 116 (3): 849-855.

DOI: 10.1115/1.2919459

[17] Alfares M A, Elsharkawy A A. Effects of axial preloading of angular contact ball bearings on the dynamics of a grinding machine spindle system [J]. Journal of Materials Processing Technology, 2003, 136 (1): 48-59.

DOI: 10.1016/s0924-0136(02)00846-4

[18] Jones A B. A general theory for elastically constrained ball and radial roller bearings under arbitrary load and speed conditions [J]. Journal of Fluids Engineering, 1960, 82 (2): 309-320.

DOI: 10.1115/1.3662587

[19] Bergman T L, Incropera F P, Lavine A S. Fundamentals of heat and mass transfer [M]. John Wiley & Sons, (2011).

[20] Thirumaleshwar M. Fundamentals of heat and mass transfer [M]. Pearson Education India, (2009).

[21] Berry M V, Lewis Z V. On the Weierstrass-Mandelbrot fractal function [C] /Proceedings of the Royal Society of London A: Mathematical, Physical and Engineering Sciences. The Royal Society, 1980, 370 (1743): 459-484.

DOI: 10.1098/rspa.1980.0044

[22] Bhushan B, Majumdar A. Elastic-plastic contact model for bifractal surfaces [J]. Wear, 1992, 153 (1): 53-64.

DOI: 10.1016/0043-1648(92)90260-f

[23] Majumdar A, Bhushan B. Fractal model of elastic-plastic contact between rough surfaces [J]. Journal of Tribology, 1991, 113 (1): 1-11.

DOI: 10.1115/1.2920588