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Ultra Precision Oil Hydrostatic Spindle Design and Metrology

Byron Knapp, Dave Arneson, Dan Oss, and Mel Liebers


Professional Instruments Company Hopkins, Minnesota, USA

A presentation given at the 10th International Symposium of Measurement Technology and Intelligent Instruments KAIST, Daejeon, Korea 01 July 2011

Professional Instruments Company Hopkins, Minnesota, USA

Byron Knapp
bknapp@airbearings.com Professional Instruments Company 7800 Powell Road Hopkins, Minnesota, USA

Snow-covered Professional Instruments headquarters, January 2011.

Ultra precision oil hydrostatic spindle


Some industrial applications demand high precision and high load capacity spindles. A bi-conic oil hydrostatic spindle is ideal for the rigorous demands of precision machining and grinding. This presentation describes an oil hydrostatic spindle that features: nanometer-level error motion high load capacity excellent dynamics high crash resistance
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Background Design Metrology

Benefits of oil hydrostatic spindles


rolling elements

Machine tool spindles commonly use rolling element bearings.

Photo credit: SKF

Some potential advantages of oil hydrostatic bearings (compared to rolling element bearings): lower error motions high damping no wear

oil hydrostatic

K Wasson. A Comparison of rolling element and hydrostatic bearing spindles for precision machine tool applications. Proceedings of ASPE Conference Precision Bearings and Spindles. June 2007.

Background

Comparison of two types of compensation


Step at the outer edge of the bearing area provides restriction. higher average pressure tighter clearances high stiffness shear film heating Orifice or slit prior to bearing pocket provides restriction. average bearing pressure less than half of supply pressure pockets affect error motion
step compensation

orifice compensation with pockets

Hale, L, Donaldson, R, Edson, S, and R Thigpen. Hydrostatic bearings designed for POGAL. Proceedings of ASPE Conference Precision Bearings and Spindles. June 2007.

Design

Comparison of two rotor configurations


H style rotor

H style uses basic geometric elements with separated axial and radial bearings. Bi-conic design offers several potential advantages: high bearing efficiency (load capacity for a given volume) high structural stiffness balance of radial, axial and tilt load capacities design simplicity

bi-conic rotor

Design

Bi-conic design with ring restrictor and pockets

Kane, NR, Sihler, J. and AH Slocum. A hydrostatic rotary bearing with angled Design surface self-compensation. Precision Engineering, 2003;27(2): 125-139.

Bi-conic with step compensation


Bi-conic with step compensation: no pocket print-through to error motion higher oil film pressure increased bearing area improved bearing stability high stiffness no complicated up-stream restrictors

20 m oil films

Design

Non-influencing, non-contact air seals

Design

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Bi-conic modal analysis


Kistler 2,000 N modal hammer Kistler 50 g K-shear accelerometer HP Dynamic Signal Analyzer

Metrology

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Outstanding dynamic response!

Metrology

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Ideal axis of rotation


An axis of rotation with pure rotation about the Z reference axis.
Rotation is the intended function of the spindle. Five other basic degrees of freedom exist: 3 linear and 2 angular.

ANSI/ASME B89.3.4M-2010. Axes of Rotation: Methods for Specifying and Testing. ASME: New York (2010).

Metrology

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Radial motions
Pure radial degrees of freedom as a function of in the X and Y directions.

ANSI/ASME B89.3.4M-2010. Axes of Rotation: Methods for Specifying and Testing. ASME: New York (2010).

Metrology

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Tilt motions
Angular degrees of freedom as a function of about the X and Y axes.

ANSI/ASME B89.3.4M-2010. Axes of Rotation: Methods for Specifying and Testing. ASME: New York (2010).

Metrology

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Axial motion
One degree of freedom as a function of in the Z direction.

ANSI/ASME B89.3.4M-2010. Axes of Rotation: Methods for Specifying and Testing. ASME: New York (2010).

Metrology

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Radial motion measurement


Measurement of the pure radial and tilt at a particular axial location.

ANSI/ASME B89.3.4M-2010. Axes of Rotation: Methods for Specifying and Testing. ASME: New York (2010).

Metrology

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Tilt motion measurement


Can be calculated from two radial measurements at specified axial locations
or two face measurements at specified radial locations.

ANSI/ASME B89.3.4M-2010. Axes of Rotation: Methods for Specifying and Testing. ASME: New York (2010).

Metrology

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Axial motion measurement


Sensor placed collinear with the axis of rotation.

ANSI/ASME B89.3.4M-2010. Axes of Rotation: Methods for Specifying and Testing. ASME: New York (2010).

Metrology

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Separating ball and spindle error


Radial motion measurements include out-of-roundness of the master and radial motion of the axis of rotation.
For nanometer-level spindles, the ball out-of-roundness can be significant. Without separation of ball out-ofroundness, the spindle error can appear better or worse.
Ball and spindle: 14 nm

Ball: 9 nm

Spindle: 8 nm

Metrology

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Reversal
Reversal techniques are theoretically the simplest way to remove artifact error. Donaldson reversal for radial motion measurements; Estler reversal for face measurements.
Both require exact artifact reversal. Potential errors from debris, handling, and remounting.
Metrology

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Multiprobe method
Sensor orientation angles affect harmonic suppression.
Asymmetric orientated measurements reduce harmonic suppression. Orientation angles of 0.000, 99.844, and 202.500 give good separation results to 225 UPR.

m A EArtifact x m B EArtifact x cos y sin

mC EArtifact x cos y sin

E Marsh. Precision Spindle Metrology. 2nd Edition. Destech Publications: Lancaster, PA (2010).

Metrology

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Lapped master
25 mm diameter ball of monolithic design for uniform circular stiffness.
Provision for balancing. Flat mounting flange with six mounting screws. Out-of-roundness is 9 nm as measured with a capacitive sensor and 150 UPR filter.

Metrology

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Error separation tooling


jig-ground locating hole (3x)

toroidal pilot

jig-ground indexing hole (4x)

Metrology

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Bi-conic spindle error measurement


MCS brushless DC motor with cooling jacket and 1,024 line count encoder Fixed displacement pump provides inlet pressures up to 70 bar with light spindle oils.
Uses 2 lpm oil (Mobile Velocite #6, viscosity 10 cSt) at 40 bar.

Metrology

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Spindle metrology setup


Lion Precision SEA software Lion capacitive sensor

Lion Elite amplifier


Custom target and error separation Stiff structural loop for testing

Metrology

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Radial error measurement

Metrology

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Axial error measurement

Metrology

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Machining results
Retrofit workhead of CNC cylindrical grinder (Parker Liberty) : Hardened 440C test piece, 75 mm diameter Better than 0.25 m out-of-roundness

0.22 m

Metrology

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Conclusions
Design and metrology techniques of an ultra-

precision oil hydrostatic spindle are described.

This spindle ideal for the rigorous demands of

precision machining, hard turning, and grinding.

Nanometer-level error motions, high load

capacity, excellent dynamics, and high crash


resistance are realized.

Conclusions

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10th International Symposium of Measurement Technology and Intelligent Instruments

Contact information:
Byron Knapp
bknapp@airbearings.com Professional Instruments Company Hopkins, Minnesota, USA

Sewon Eng. LTD


www.sewoneng.net Seoul, Korea

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Bonus features.

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Grinding wheelhead

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Grinding the cone

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Continuing work: lathe retrofit

Goals: demonstrate advantages of precision hydrostatic spindle retrofitted into a standard lathe for hard turning.
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Stiffness and load capacity (40 bar bearing inlet pressure).

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3 decimal places on the angle?


Zeiss Contura G2 Inspection Report

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