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The Open Mechanical Engineering Journal, 2008, 2, 32-39 32

Open Access
Vibration in a Cracked Machine Tool Spindle with Magnetic Bearings
Huang-Kuang Kung and Bo-Wun Huang*

Department of Mechanical Engineering, Cheng Shiu University, Taiwan

Abstract: Due to manufacturing flaws or cyclic loading, cracks frequently appear in a rotating spindle system. These
cracks markedly affect the dynamic characteristics in higher modes of the rotating machinery. For faster rotational speeds,
especially for super-high-speed cutting, a spindle with magnetic bearings is necessary. However, most investigations into
spindle system dynamic characteristics have been confined to ball-bearing-type spindles. The dynamic response of
rotating cracked spindle systems with magnetic bearings is examined in this article. A Euler-Bernoulli beam of circular
cross section is used to approximate the spindle and the Hamilton principle is employed to derive the equation of motion
for the spindle system. The effects of crack depth, rotation speed and bearing length on the dynamic response of a rotating
magnetic bearing spindle system are studied.

INTRODUCTION used for the spindle and rotor in high speed rotating
machinery.
Cracks frequently appear in rotating machinery due to
manufacturing flaws or cyclic fatigue during operation. Traditionally, ball bearings have been used to support the
Numerous cracks can be observed after severe operating spindle systems when the rotational speed was not high.
conditions, especially in high speed spindles [1, 2]. Local Previous investigations on bearing spindle systems were
structural irregularities caused by cracks in the spindle may confined to spindles with ball bearings. In some studies, the
significantly change the dynamic behavior of a rotating focus was on the dynamic response of a spindle supported by
machinery system. The effects of cracks on the dynamic bearings [10, 11]. At higher speeds, this bearing changes the
and static behaviors of structures have been studied by a stiffness of the entire spindle system and significantly alters
number of researchers [3-5]. The effects of cracks on the system properties [12-15]. Precise machining requires
spindle dynamics, shaft and rotor systems, were also higher spindle speeds, making the magnetic-bearing spindle
studied by researchers [6-9]. When a spindle rotates, the necessary. Investigations as [16-20] studied the performance
vibrational response is altered by the crack opening and and dynamic properties of magnetic bearings. Most studies
closing in each cycle. Most investigations were motivated deal with a magnetic ring for a radial magnetic bearing used as
by the hypothesis that only opening cracks markedly an unlimited one long magnetic bar for a permanent magnetic
change the spindle dynamics. This paper focuses on the bearing. Investigation as [21] studied the bearing capacity and
dynamics of a spindle with a transverse crack. stiffness of radial magnetic bearings.
High speed machining is one of the most modern Thus far, most investigations as [22-24] on the dynamic
manufacturing engineering technologies. In a machining characteristics of a cracked spindle system were limited to
system, the spindle is the most critical element that affects ball-bearing-type spindles. This study examines the crack
the dynamic performance and capabilities of the system in effects on the dynamic response of a rotating spindle system
the machining process. However focusing exclusively on with magnetic bearings. A Euler-Bernoulli beam of circular
the spindle system is insufficient because the bearings can cross section was used to approximate the spindle model. The
change the dynamics of a machining spindle system. equations of motion for the bearing-spindle system were
Hence, the bearing effects on the spindle system must also derived using the Galerkin method and Hamilton principle. A
be considered. Bearings are used in many rotating model the size of an actual spindle system was used. To
machines to brace the rotating spindles and rotors. In the simplify the calculations, massless springs were employed to
past, the required rotor speed was low, allowing ball and model the stiffness of the magnetic bearings. The effects of
roller bearings to be used in rotating machinery. High crack depth, rotational speed and bearing length on the
temperatures are generated with ball-bearing spindle dynamic response of a spindle system were investigated.
systems operating at high speeds. The high temperatures
often bring about machine failure. To attain greater
complexity and accuracy, modern engineering technologies
demand machinery that can be run at high speeds. To avoid
the high temperatures generated by the contact between the
spindles and bearings, non-contact magnetic bearings are

*Address correspondence to this author at the Department of Mechanical


Engineering, Cheng Shiu University, Taiwan;
E-mail: huangbw@csu.edu.tw a spindle supported by bearings

1874-155X/08 2008 Bentham Open


Vibration in a Cracked Machine Tool Spindle with Magnetic Bearings The Open Mechanical Engineering Journal, 2008, Volume 2 33

kx1 : the bearing stiffness in u deflection at a position z1 ,


ky1 : the bearing stiffness in v deflection at a position z1 ,
kx 2 : the bearing stiffness in u deflection at a position z2 ,
ky2 : the bearing stiffness in v deflection at a position z2 ,
 : density ,
A : cross section area,
 : rotating speed,
 ( ) : Dirac delta fuction,
z1 : the first located position of bearings,
z2 : the second located position of bearings.
For convenience, the dimensionless equations of motion
for this spindle are:

EI  2
( )
a simple model of bearing spindle system
u  2
EI
 v + 
  u + u 
Fig. (1). A rotating spindle with bearings scheme.  AL4  AL4  (3)
η ( ) (
+k x1 u  z  z1 + k x 2 u  z  z2 )} = 0
EI  2
a
dξ v + 2
EI
 AL4
 u +   v + v 
 AL4 

( ) (4)
( )
+ k y1 v  z  z1 + k y 2 v  z  z2( )} = 0
ξ
o where the dimensionless parameters are given using:

z z z EI
z= , z = 1 , z = 2 , = , (5)
L 1 L 2 L  AL4
R
( ), v ( ), k k x1 L3
( ) ( )
u z v z
Fig. (2). Geometry of a cracked spindle. u z = z = x1
= , (6)
L L EI
Theory
This paper considers a spindle supported by magnetic k x 2 L3 k y1 L3 k y 2 L3
bearings, as shown in Fig. (1a), to elucidate the dynamic kx 2 = , k y1 = , ky2 = (7)
EI EI EI
response of a spindle system. Fig. (1b) presents a simple
model for this bearing-spindle system. In this model, and the boundary conditions are:
massless springs are employed to simulate the stiffness of
the magnetic bearing and support the spindle. The u  = u  = v  = v  = 0 , at z = 0 (8)
rotational speed  of the spindle cannot be ignored in the u  = u  = v  = v  = 0 , at z = 1 (9)
rotating machinery bearing application. In this study, the
deflection components (z,t), and u(z,t) denote the two The Galerkin method is employed to derive the spindle
transverse flexible deflections of the spindle system. E and equations of motion in matrix form. Therefore, the solutions
I represent the Young’s Modulus and area inertia of the for Eqs. (3) and (4) can be assumed to be:
spindle, respectively. Only the transverse flexible
( ) ( ) ()
m

deflections are studied in this article. u z ,t =  i z pi t (10)


i=1
According to [25], the governing equations of the
( ) ( ) ()
m
spindle system are displayed as:
v z ,t =   i z qi t (11)
u  2  A v   A 2 u + EI u  ( )
i=1
 A
(1) ( ) ( )
where  i z , i z are comparison functions for the spindle
( ) (
+ k x1 u z  z1 + k x 2 u z  z2 = 0 ) () ()
system, and pi t , qi t are the time coefficients to be
determined for the system. The exact solution for a beam with
v + 2  A u   A 2 v + EI v  
 A ( ) (2)
free-free boundary conditions is considered, and five
comparison function modes are used.
( ) (
+ k y1 v z  z1 + k y 2 v z  z2 = 0 )
( ) ( ) ( ) (1  cosh  z cos  z )
2
 i z =  i z = i z i i
(12)
where
34 The Open Mechanical Engineering Journal, 2008, Volume 2 Kung and Huang

 3  0 G  
i =  i    u* i  2 , i = 1, 2, 3, 
 2
( ) (13) G  = 2  1
 (27)
 G  0 
 
()
2
*
where u is the unit step function. Substituting Eqs.
(10) and (11) into Eqs. (3) and (4) respectively, the   K e  0    K  0 
equations of motion in matrix form for the spindle system  K  =  1
 +  2   1 
 0  K e    0  K   
can be derived as:  2   2  (28)
  K s1     K s2  
  M


0
 

p t ()  0 G

 p t () + 1
0
+ 1
0

 + 2  
1 1

 0

 M

2
q t
  ()  G

 2
0 q t
  ()  0

 K s1 
2
  0
 
 K s2  
2 

  K e

+ 2 
0
 p t

()
  K 
0
 p (t ) A space vector is introduced in Eq. (25) to solve the
+   
1 1

2 2

 0

 K e
 q t 
2 ()
 0  K 
 q
2
(t )  (14) eigenvalue problem for the system.
  K s1
0
 p t ()
 K
0
 p t ( ) = 0  
+ 2 
 0
1

 K s1
q t 
2  s2 1
+ 
 0 ()

 K s2
q t

( ) 
{V } =  XX  . (29)
 2  2  
Substituting Eq. (29) into Eq. (25), the equation can be
rearranged as;
EI
where  = .
 AL4   M  0    G   2  K  
  V +   
{ }  V =0 { } (30)
The elements of the matrices in the above equation are  0  2  K     2  K  0 
given as follows,
The non-dimensional frequency  n in Eq. (30), i.e., the
(m ) i  j dz =   k ( ) 
1
ij 1
=  0  ij 1
(15) natural frequency of the spindle system, is defined as:

EI
( )  i  j dz =   k ( )  n = n / for n = 1,2,..... (31)
1
mij
2
=  0  ij  2
(16)  AL4

(g )
1 In industry, ball bearings are frequently used to support
ij 1
=   i  j dz (17) rotating spindles in rotating machinery. Recently, magnetic
0
bearings have been employed increasingly to support spindles
(g )
1
ij 2
=  0
 i  j dz (18) because they must rotate at higher speeds. Few investigations
focused on the dynamic responses of defective spindle systems
with magnetic bearings. Therefore, this investigation addresses
( )
 k  = 1

 e ij 1  0
i j dz (19) the dynamic response of a cracked spindle supported by
magnetic bearings.
( )
 k  = 1

 e ij 2  0
 i j dz (20) Crack Effect
Considering a crack located at z = z * on this spindle, the
( )
 k  =k  z { ( )} { ( z )}
T
(21) strain energy of the defective spindle will include the released
 s1 ij 1 x1 i 1 j 1
energy caused by the crack. Fig. (2) shows the geometry of a
cracked spindle. The released energy caused by a crack, as
( )
 k  =k  z { ( )} { ( z )}
T
(22) noted in [26], with a depth of a may be expressed as:
 s1 ij  2 y1 i 1 j 1

b
(1  μ ) K ( )d
2

( )
 k  =k  z { ( )} { ( z )} =
T c 2
(23) U I
(32)
 s2 ij 1 x2 i 2 j 2
b
E

( )
 k  =k  z { ( )} { ( z )} ( )
T 2
(24) where b = R2  R  a
 s2 ij 2 y2 i 2 j 2

For the sake of convenience, Eq. (14) can be rewritten and μ is the Poisson's ratio of the spindle, K I is the stress
as, intensity factor under a mode I load and R is the radius of the
spindle. In this case, the stress intensity factors K I can be
{ }
 M  X +  G  X +  2  K  X = 0 { } { } (25) approximated as
where
  M  0 
KI  = ()
4 Mb
R 4
R 2   2  F2  ( h) (33)

 M  =  1
 (26) where, M b is the bending moment, and
 0  M  
 2 
h = 2 R2   2 (34)
Vibration in a Cracked Machine Tool Spindle with Magnetic Bearings The Open Mechanical Engineering Journal, 2008, Volume 2 35

 = a + R2   2  R EI 2
(35)
u  2
EI
 AL 4
 v + 4 
 AL 
  u + u   ( )
4
  
  
0.923+ 0.199 1 sin  
 2h  
8R
( )
1  μ Q1 ,  u  z  z * 
2 
( )
( )  

(44)
F2  =
2h L
R R 
tan  (36)
 2h
h   

cos 
 2h
( )
+k x1 u  z  z1 + k x 2 u  z  z2 = 0 ( )}
EI 2
The notations a and R are the maximum crack depth
and radius of the spindle, respectively. Based on the inves-
v + 2
EI
 AL4
 u +   v + v 
 AL4 

( )
tigations in [26, 27], alterations of the elastic deformation
  
energy caused by lateral bending moments are the only
important changes in the case of slender beams with a

8R
L
(
R R
)
1  μ 2 Q2 ,  v  z  z * 

( ) (45)

v  ( z  z )} = 0
crack. The released energy of the crack with respect to 
due to the bending moment is obtained as: (
+ k y1 v  z  z1 + k y 2 ) 2

2 Similarly, the equations of motion for the defective spindle,


 2 v
( ) ( )
L a b

U c = E 1  μ 2 

 2 zz
* i.e. Eq. 13, can be rearranged in matrix form using Galerkin’s
0 0  b z (37) method as follows:
( 2 2
)
R    F22  d d dz
h ( )   M
 1
0 


()
p t 

 + 2
 0

G 
p t 

1
 
()
Similarly, the released energy of the crack with respect
 0

 M
2

q t

()

 G
 2
0
q t

 ()
to  is derived as follows,
+ 2 
  K e 0 
p t 


()  K
2 2   1
0
+  
1

 2u
2
 0  K e
q t 
()  0  K 
( ) ( )
L a b
 2  2
U c = E 1  μ 2 
z  z  z* (46)
2
 (38) ()

p t 
 K
2  c 1
0 
p t 
()
 K
2  s1 1
0

( h ) d d dz
0 0 b
    + 
 2 F12  ()

q t
  0

 K c
q t

2 ()
 0  K s1
2



p ( t ) 
  K s2 0 
p ( t ) 

where  
+ =0
1

2


q ( t )
  0

 K s2
q ( t )


( h) =  

2
2h
F1  tan 
  2h where


  

0.752 + 2.02  + 0.37 1  sin  
3

(39)
( )
k  = (
8R 1  μ 2 )Q   , 
( ) ( )
  z  j z  *
 2h   R (47)
 h
c ij 1 L 1
R
i  z =z
 

cos 
 2h ( )
k  = (
8R 1  μ 2 )Q   , 
( ) ( )
  z  j z  * (48)

c ij  2 L 2  R R
i  z =z
For simplification, the dimensionless equations are
employed as: Supported by Magnetic Bearing
2
2u     Few investigations on radial magnetic bearings were found,
( ) ( )
1
4R
U c = 1  μ 2   2  z  z *  Q1 ,  dz (40) so these bearings were selected for this article. The rotor is
L 0 z 
R R kept in the desired position by a magnetic bearing stator using
2
a magnetic field induced by permanent magnets. According to

2 v    
( ) ( )
1
4R [21], the bearing force Fr is derived as follows,
U c = 1  μ 2  2  z  z *  Q2  ,  dz (41)
L 0 z  R R Br 1 Br 2
Fr = S (49)
where 4μ0

  
( )
a Rb R
2  2    Where Br 1 : remanence of the external magnetic loop for the
Q1  ,  =
 R R   F
R2 R 1 h
d d
R R
(42) magnetic bearing; Br 2 : remanence of the internal magnetic
0 0 loop for the magnetic bearing; μ0 : permanence in vacuum
and,
    2   2   
( )
a R b R

Q2  , =
 R R
 0
 1  R 2 R F2
b R 
h
d d
R R
(43)
(
S = S23 + S14  S13  S24 ) (50)

( ) + ( e + R cos   R )
2 2
The bearing-spindle with a crack can be obtained as: Rx1 = x1 + x0  x 3 2
cos 
(51)
+ ( R sin   R sin  )
2
3 2
36 The Open Mechanical Engineering Journal, 2008, Volume 2 Kung and Huang

( ) + ( e + R cos   R cos  ) size actually used in engineering applications are addressed


2 2
Rx2 = x1 + x0  x 3 1
(52) and a magnetic bearing is considered in this work. The
+ ( R sin   R sin  )
2
dimensions R=0.02m and L=0.2m of a rotating spindle are
3 1
assumed. The bearings positions are assumed to be z1 = 0 and
( ) + (e + R )
2 2
Rx3 = x1 + x0  x 4
cos   R1 cos  z2 = 1 .
(53)
+ (R sin   R sin  )
2
A spindle system braced by a magnetic bearing is
4 1
important in engineering applications, especially for high-
( ) + (e + R ) speed rotational machinery. For the above-mentioned spindle
2 2
Rx4 = x1 + x0  x 4
cos   R2 cos  dimensions, the important magnetic bearing parameters were
(54)
+ (R sin   R sin  )
2 selected as follows. Nd-Fe-B material was employed to model
4 2 the elements of a permanent magnet in the radial magnetic
2 2 lm lm
bearings. For this material, the remanence Br 1 = Br 2
S23 =     = 1.13 wb m2 can be shown. Corresponding to the spindle
imension, the length of the magnetic lm = 20mm and the
0 0 0 0

(
R2 R3 e + R3 cos   R2 cos  d d  dxdx1 ) (55)
clearance Lmg = 0.001m were assumed.
Rx13/ 2 Q2
2 2 Q1
S13 =    
lm lm

0 0 0 0 10
R1 R3 (e + R3 cos   R1 cos  ) d d  dxdx1 (56)
Rx2 3 / 2 1

2 2 lm lm
S14 =    
0 0 0 0 0.1

(
R1 R4 e + R4 cos   R1 cos  d d  dxdx1 ) (57)
0.01
Rx33/ 2
2 2 lm lm
S24 =    
0.001
0 0 0 0

(
R2 R4 e + R4 cos   R2 cos  d d  dxdx1 ) (58)
0.0001
0 0.2 0.4 0.6 0.8 1
Rx4 3/ 2
Crcak depth a / R
where R1 : external radius of the external magnetic Fig. (3). The variations in the crack flexibility with the crack depth
loop R + 2hg + Lmg ratio.

R2 : internal radius of the external magnetic The variation in the crack flexibility with the crack depth
loop R + hg + Lmg ratio is plotted in Fig. (3). The numerical analysis reveals that
the crack flexibility increases as the crack depth is increased.
R3 : external radius of the internal magnetic loop R + hg From the results, the crack depth markedly affects the shaft
stiffness. As a whole, these results and those from previous
R4 : internal radius of the internal magnetic loop R investigation [29] are identical. Fig. (4) presents the natural
lm : length of the magnetic loop frequencies of a spindle bearing system with and without
cracks. The logarithmic scale was employed to study higher
Lmg : clearance between the internal and external magnetic modes in this figure. At lower modes, the natural frequencies
loops of the spindle bearing system change slightly regardless of
hg: the thickness of the magnetic loop whether there is a crack or not in the system. However, at
higher modes, the natural frequencies of a spindle bearing
e : is eccentric of the magnetic bearing system decrease when there is a crack in this spindle system.
Consequently, the stiffness of a radial magnetic bearing With magnetic bearings, the crack effect on the dynamics of a
can be derived as follows: spindle system has more influence at the higher modes than at
the lower modes. The effect of the crack depth on the natural
Fr Br 1 Br 2 S frequencies is considered in Fig. (5). In this figure, the lower
km = = (59) and higher mode natural frequencies, the 1st and 5th modes, are
e 4μ0 e
studied together. Both the 1st and 5th natural frequencies
decrease with increasing crack depth. If the crack depth were
ANALYSIS AND DISCUSSION   0.1 , the crack size would have little influence on the
In ultra-high-speed machining, using magnetic bearings natural frequencies of a rotating blade system. However, the
to support the spindle is necessary [28]. The dynamic natural frequencies are depressed significantly when the crack
properties of a multi-mode spindle with bearings of the size is larger than 0.1.
Vibration in a Cracked Machine Tool Spindle with Magnetic Bearings The Open Mechanical Engineering Journal, 2008, Volume 2 37

natural frequencies of the system is the lowest when the crack


no crack
is located at the middle of the spindle. The phenomena
with a crack a D = 0.2 5 illustrated in Fig. (6a) and (6b) are similar. The effect of
100 rotation speed on the dynamics of a cracked spindle with
magnetic bearings is plotted in Fig. (7). Double roots for the
natural frequencies of a cracked spindle with magnetic
bearings are observed only if this system has no rotation speed.
10 With rotation speed, the natural frequencies of this system are
divided into two parts, the forward and backward frequencies.
Only the 1st and 2nd natural frequencies are shown in this
figure. The 1st natural frequency of a cracked spindle with
1 magnetic bearings increases as the rotational speed increases.
However, it was found that if the rotational speed increases,
the 2nd natural frequency decreases.
0.41
0.1
0 1 2 3 4 5 6 7
0.4095
Mode Number
Fig. (4). The natural frequencies of a magnetic-bearing spindle 0.409
with and without a crack, (  = 0.5, a D = 0.25, z * = 0.5 ).
0.41
0.4085

0.408
0.4075
0.4075

0.405 0.407
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
Crack location z *
0.4025 (a) the 1st mode

24
0.4
0 0.05 0.1 0.15 0.2 0.25 0.3
22
Crack depth a / D
(a) the 1st mode 20

25 18

16
20
14

15 12

10
10 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
Crack location z *
5 (b) the 5th mode
Fig. (6). The natural frequencies of a magnetic-bearing spindle with
0 different crack locations, (  = 0.5, a D = 0.25 ).
0 0.05 0.1 0.15 0.2 0.25 0.3
Crack depth a / D For radial magnetic bearings, the length of the bearings
(b) the 5th mode remarkably alters the system stiffness. Fig. (8) illustrates the
variations in natural frequencies for a cracked spindle with
Fig. (5). The natural frequencies of a magnetic-bearing spindle different magnetic bearing lengths. The results indicate that the
with different crack depths, (  = 0.5, z * = 0.5 ). natural frequencies of a magnetic-bearing spindle increase as
the magnetic bearing length increases. Finally, the frequency
Crack location dramatically changes the dynamics of a responses of a spindle system with and without cracks are
spindle with magnetic bearings. Fig. (6) shows the illustrated in Fig. (9). Both the lower and higher frequency
variation in the natural frequencies of a spindle with domains were examined. In the lower frequency domain, the
different crack locations. As mentioned above, only the 1st figure shows that the frequency response of a bearing-spindle
and 5th natural frequencies were examined. When the crack system without a crack is almost the same as one with a crack.
is located at both ends, the natural frequencies are almost The peak frequency response values for a spindle with
the same as a system without a crack. The value of the magnetic bearings are depressed in the higher frequency
38 The Open Mechanical Engineering Journal, 2008, Volume 2 Kung and Huang

domain if there is a crack in the spindle. As above, the


with a crack
effect of a crack may significantly influence the dynamics without cracks
of a spindle system with magnetic bearings at higher
30
modes.
the 1st mode 20

the 2nd mode 10


1.8
0
1.6

1.4 -10

1.2 -20
1
-30
0.8
-40
0.6 0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
0.4 Frequency
(a) a lower frequency domain
0.2

0 -50
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
Rotational speed Ω -45
Fig. (7). The natural frequencies of a magnetic-bearing spindle
with different rotational speeds, ( z * = 0.5, a D = 0.25 ). -40

1
-35
0.9
0.8 -30
0.7
-25
0.6
0.5
-20
0.4 15 16 17 18 19 20 21 22 23
Frequency
0.3
(b) a higher frequency domain
0.2
Fig. (9). The frequency response of a rotating spindle with and
0.1 without a crack, (  = 0.5, a D = 0.25, z * = 0.5 )
0
0 0.01 0.02 0.03 0.04 0.05 4. The crack will dramatically affect the dynamic
Length of bearing m characteristics of a spindle with magnetic bearings if the
crack is located at the middle of the spindle.
Fig. (8). The natural frequencies of a rotating cracked spindle
with different lengths of magnetic bearing,
( z * = 0.5, a D = 0.25 ). REFERENCES
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Received: November 02, 2007 Revised: April 08, 2008 Accepted: May 13, 2008

© Kung and Huang; Licensee Bentham Open.


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