The Evaluation of Performance of Spindle Connector and its Finite Element Analysis

Abstract

The rapid development of machining technology and reliable high-speed machining systems has led to a fast operation of machines. However, machining machines cannot still meet modern requirements in terms of the quality of parts, the machine components, and the life of the tools. The major components of the machining system are machine tools, the spindle interfaces (the contact between the spindle and the tool holder), and tools. The choice of the spindle connector is the main decision, as this defines the limitation of the metal cutting efficiency and considerably influences the deformation of the machine tool. Therefore, it is very critical to select the optimal industry spindle connector, which should provide high stiffness. The purpose of this study is to develop bending testing technologies and characterization methodologies for various spindle connectors. A bending testing fixture has been designed for various spindle connectors using MTS 810 as the basic equipment. The displacements have been measured by the designed fixture and the tool tilting values have been determined based on the measured displacements and the distance of the LVDT sensors. ABAQUS is used to simulate the bending test. The average tool tilting values of the KM4X100 with the standard clamping force of 100 kN are 0.376 mm/m, 0.2755 mm/m, and 0.191 mm/m at 4600 N-m, 4100 N-m, and 3500 N-m applied bending moment, respectively. By reducing the clamping force to 80 kN, the average tool tilting value of the KM4X100 is 0.347 mm/m at 3500 N-m applied bending moment. The tool tilting values are influenced by the applied bending moment and the clamping force. The average tool tilting value of the C10 with the standard clamping force is 0.3955 mm/m at 3500 N-m applied bending moment. At each standard clamping force and 3500 N-m applied bending moment, the KM4X100 exhibits approximately 49% less tool tilting value than the C10. At a clamping force of 80 kN and a bending moment of 3500 N-m, the KM4X100 has approximately 14% less tool tilting value than the C10. The tool tilting values evaluated by the finite element analysis (FEA) agrees well with the experimental within the error of 8%. The findings can be used to provide the database for the various spindle connector. In this study, the bending testing of spindle connectors has been developed.