Thermal Modeling Challenges of High-Speed Motorized Spindles

Abstract This paper investigates the thermal modeling challenges of high-speed motorized spindles up to 40,000 rpm. The expansion and deflection are critical determinants for resulting tool center point displacement achievable machining accuracy machine tools. In order compensate, finite element reduced physical models (digital twins) therefore require an accurate understanding boundary conditions. spindles, heat sources great significance temperature field. However, it is very difficult accurately quantify in spindles. a particular challenge applications exceeding 20,000 rpm, where commonly used conditions not validated. While power loss electric motor could be quantified with reasonable accuracy, calculation approaches air bearing friction proved inadequate. introduces improved method was verified based on coupled thermal/fluid-mechanical spindle simulation model. mean absolute difference between model test bench 1.5 K.