Analytical Method and Experimental Verification of Aerostatic Spindle Design Based on the Coupling Effect of Ultra-precision Grinding

doi:10.3901/JME.2025.05.040

Abstract

Abstract: The utilization of aerostatic spindles in various applications is accompanied by the presence of coupling effects at the spindles and the machining system during the machining process. These coupling effects inherently result in a decrease in the spindle rotational motion accuracy, subsequently introducing additional errors significantly influencing both the machining process and the precision of the workpiece. The phenomenon of coupling in ultra-precision internal grinding might result in alterations to the rotary precision of the aerostatic spindle. This research presents a novel modeling approach for investigating the coupling effects of the aerostatic spindle rotary and its impact on the grinding process. The comprehensive analysis of the grinding system, which includes the workpiece spindle and the grinding wheel spindle, is conducted. The research investigates the utilization of the developed ultra-precision internal grinding machine to provide a comprehensive explanation of the process. To assess the impact of the aerostatic bearing parameters and the grinding process on the dynamic response of the spindle, a double-rotor coupling model is established. Furthermore, an analysis is conducted to examine the impact of the coupling effect on the surface topography at the submicron scale. The influence of bearing settings and dynamic grinding force on spindle vibration, which can lead to a degradation in machining quality, has been observed. Additionally, the final surface topography is defined through the coupling effects of the grinding system and the grinding process. The study concluded with the execution of machining experiments, wherein the roundness error of the machined surface was determined using spectral analysis. The obtained results from both the experimental and analytical approaches exhibited consistency, thereby confirming the reliability of the employed method. This research holds substantial importance in the realm of high-precision aerostatic spindles design and provides valuable insights into the coupling effects between the workpiece spindles and wheel spindles within the grinding system.

Key words: aerostatic spindle, the coupling effect, ultra-precision internal grinding, rounding accuracy, multiscale modelling and design analysis

CLC Number:

TG502

YUE Songjie, CHENG Kai, BAI Qingshun, DING Hui, ZHAO Liang, GAO Siyu. Analytical Method and Experimental Verification of Aerostatic Spindle Design Based on the Coupling Effect of Ultra-precision Grinding[J]. Journal of Mechanical Engineering, 2025, 61(5): 40-49.

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