Optimization of Factors Affecting Vibration Characteristics of Unbalance Response for Machine Motorized Spindle Using Response Surface Method

Elhaj A I Ahmed,Li Shusen

doi:10.1155/2019/1845056

Elhaj A I Ahmed, Li Shusen

Open Access

https://doi.org/10.1155/2019/1845056

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Abstract

In this study, the response surface (RS) method and forced rotordynamic analyses together with Finite-Element-Analysis (FEA) have been established to optimize the factors affecting the vibration characteristics. The spindle specification, bearings locations, cutting force, and motor-rotor unbalance mass are proposed to represent the design factors and then they are utilized to develop Machine Motorized Spindle (MMS). The FEA-based Design of Experiment (DOE) is adopted to simulate the output responses with the input factors, wherein these DOE design points are used to carry out the RS models to visualize more obvious factors affecting the dynamic characteristics of MMS. The sensitivities of these factors and their contributions to the vibration of imbalance response have been evaluated by using the RS models. The simulation results show that the motor-rotor shaft inner diameter, the distance of the back bearing location, and the rotating unbalance-mass are highly sensitive to the vibration characteristics compared to the other factors. It is found that more than two-fifths of total vibration response amplitude has been conducted by induced rotating imbalance mass. The results also showed that the proposed factors optimization method is practicable and effective in improving the vibration response characteristics.

Highlights

In the machined component, the machining accuracy is most critical and is related to several factors, wherein these factors include thermal error, positioning error, tool-holder and rotating unbalance force induced error, and motion error [1]
After the design space is sampled in Design of Experiment (DOE), the responses dataset can be obtained through the finite element model (FEM) simulation
To evaluate the sensitivities of factors on the vibration responses, the variation of input with output responses is graphically presented based on genetic-aggregation method

Summary

Introduction

The machining accuracy is most critical and is related to several factors, wherein these factors include thermal error, positioning error, tool-holder and rotating unbalance force induced error, and motion error [1]. Because of complex structures of MMS, the optimization of parameters affecting its dynamic characteristics due to motor-rotor unbalance induced is much difficult [5]. The effects of design variables or operation parameters on system dynamics response have been covered with the inclusive variety of researches [6,7,8,9,10,11,12]. These previous researches were focused on improving the dynamic performances of highspeed (HS) motorized spindle through optimizing the design factors. Lee et al [20] proposed a design optimization method to reduce the mass of a flexible rotor supported in ball bearings via rotational velocities and Protection Flange

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Conclusion