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Stability analysis and enhancement of five-degree-of-freedom composite spindle with active magnetic bearing support

Authors:
Salwa Benali at École Nationale d'Ingénieurs de Gabès
Salwa Benali
Anoire Ben jdidia at Institut Supérieur de Mécanique de Paris
Anoire Ben jdidia
Taissir Hentati at University of Sfax
Taissir Hentati
Slim Bouaziz at University of Sfax
Slim Bouaziz
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Abstract and Figures

Unstable spindle rotation can result in vibrations, chatter, and increase in surface roughness, leading to productivity reduction and energy consumption rise. The combined effects of nonlinearity owing to different bearing types and spindle materials significantly impact the stability of the machine tool spindle system, which needs to be considered during the machine tool design process. This paper focuses on the stability analysis of a milling machine tool spindle. From this perspective, the dynamic behavior of the rotating shaft was investigated through analyzing the vibrations using a homogenized finite element beam model with five degrees of freedom at each nodal point. The study encompasses the Campbell diagram and stability analysis of the shaft considering three types of spindle materials (composite, steel, and functionally graded materials) as well as three types of bearings (rigid, active magnetic, and rolling bearings). The comparison between all structures stabilities conducted us to the best combination. In fact, the composite type affects the instability level. Additionally, the paper examines the influence of AMB properties, composite material characteristics and cutting parameters on natural frequencies, critical speeds, and instability thresholds of the composite spindle the findings indicated that the stability of the composite rotor is highly affected by the parameters related to the laminate composition, the parameters of the AMB and the cutting parameters. Furthermore, results indicate that increasing the control current (I0), number of turns (N), air gap (C), feed per tooth (fz), number of teeth (Nf) and axial depth (ap) enhances the stability of the composite spindle.
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Content available from International Journal on Interactive Design and Manufacturing (IJIDeM)
This content is subject to copyright. Terms and conditions apply.
International Journal on Interactive Design and Manufacturing (IJIDeM) (2025) 19:4649–4661
https://doi.org/10.1007/s12008-024-02107-3
REVIEW
Stability analysis and enhancement of five-degree-of-freedom
composite spindle with active magnetic bearing support
Salwa Benali1,2 ·Anoir Ben Jdidia1·Taissir Hentati1·Slim Bouaziz1·Mohamed Haddar1
Received: 22 February 2024 / Accepted: 11 September 2024 / Published online: 20 September 2024
© The Author(s), under exclusive licence to Springer-Verlag France SAS, part of Springer Nature 2024
Abstract
Unstable spindle rotation can result in vibrations, chatter, and increase in surface roughness, leading to productivity reduction
and energy consumption rise. The combined effects of nonlinearity owing to different bearing types and spindle materials
significantly impact the stability of the machine tool spindle system, which needs to be considered during the machine tool
design process. This paper focuses on the stability analysis of a milling machine tool spindle. From this perspective, the
dynamic behavior of the rotating shaft was investigated through analyzing the vibrations using a homogenized finite element
beam model with five degrees of freedom at each nodal point. The study encompasses the Campbell diagram and stability
analysis of the shaft considering three types of spindle materials (composite, steel, and functionally graded materials) as well
as three types of bearings (rigid, active magnetic, and rolling bearings). The comparison between all structures stabilities
conducted us to the best combination. In fact, the composite type affects the instability level. Additionally, the paper examines
the influence of AMB properties, composite material characteristics and cutting parameters on natural frequencies, critical
speeds, and instability thresholds of the composite spindle the findings indicated that the stability of the composite rotor is
highly affected by the parameters related to the laminate composition, the parameters of the AMB and the cutting parameters.
Furthermore, results indicate that increasing the control current (I0), number of turns (N), air gap (C), feed per tooth (fz),
number of teeth (Nf) and axial depth (ap) enhances the stability of the composite spindle.
Keywords Campbell diagram ·Stability analysis ·Composite spindle ·Machine tool ·Dynamic behavior ·Active magnetic
bearing
1 Introduction
Vibration and instability correspond to critical issues within
the realm of machine tools that can significantly impact
BSalwa Benali
salwa.benali96@yahoo.com
Anoir Ben Jdidia
anoir.benjdidia@gmail.com
Taissir Hentati
Taissir.hentati@enis.tn
Slim Bouaziz
slim.bouaziz@enis.tn
Mohamed Haddar
mohamed.haddar@enis.rnu.tn
1Laboratory of Mechanical Modeling and Production
(LA2MP), National School of Engineers of Sfax (ENIS),
Sfax, Tunisia
2National School of Engineers of Gabés (ENIG), Sfax, Tunisia
their performance, accuracy, and reliability. These vibrations
often result from dynamic forces generated during operation
including cutting forces, rotating spindle, and bearing forces.
Extensive research has been conducted to develop analytical
models, experimental techniques, and control strategies in
order to mitigate vibration and prevent instability. Against
this background, an optimization methodology was set for-
ward by Jakeer Hussain Shaik et al. [1] considering the
spindle and tool parameters as design variables to enhance
the dynamic stability of the shaft rotation system. The find-
ings of their study provided valuable insights into optimizing
the design of spindle-tool systems, ultimately enhancing
their performance and reliability in machining processes.
Another research performed by Jakeer Hussain Cheikh et al.
[2] contributes to understanding and optimizing the stability
of modified drilling machines, offering deeper insights into
their design and operation. This finding highlights the poten-
tial of using microphone signals as a valuable tool in terms of
monitoring and assessing stability during drilling processes.
123
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