GOALI/IUCP: Inherently Reliable Motorized Spindles for High-Speed Machining

高速加工是一种有潜力大幅度缩短加工时间，提高产品精度和表面光洁度，并消除一些精加工工序的技术。高速加工的主要问题之一是开发具有足够可靠性的主轴以承受高加工速度。这个GOALI项目的目标是开发一种高性能的主轴原型，它本身是可靠的，对生产误差有很高的容错能力，并研究其在高速、高可靠性工艺中的实施问题。研究任务包括：1)建立整个电主轴系统的电-热-机械模型，用于设计灵敏度分析；2)利用该模型和新设计开发固有可靠的主轴原型；3)开发基于多传感器的主轴/过程监视器。该项目将由普渡大学和辛辛那提米拉克龙公司联合执行。该项目预计将对下一代高性能机床的设计产生重大影响。从该项目中获得的主轴动力学、热行为和对主轴可靠性至关重要的工艺因素的知识，可以减少因意外过早失效而导致的生产损失、主轴库存和主轴修复成本。

DMI-9734914 Tu High speed machining is a technology that has the potential of drastically reducing machining time, improving product accuracy and surface finish, and eliminating some finishing processes. One of the major problems in high-speed machining is the development of spindles with sufficient reliability to afford the high machining speed. The objective of this GOALI project is to develop a high-performance spindle prototype which is inherently reliable with high forgiveness for production error, and to study issues related to its implementation to high-speed, high-reliability processes. The research tasks include: 1) Development of an electro-thermo-mechanical model of an entire motorized spindle system for design sensitivity analysis, 2) Development of an inherently reliable spindle prototype using the model and new designs, and 3) Development of a Multiple-sensor based spindle/process monitor. The project will be performed jointly by Purdue University and Cincinnati Milacron Inc. The project is expected to have significant impact on the design of next-generation, high-performance machine tools. The knowledge of spindle dynamics, thermal behavior, and process factors critical to spindle reliability obtained from the project could reduce the cost of lost production, spindle inventories, and spindle rehabilitation due to unexpected premature failures.