Load-Dependent Rotating Performance of Motorized Spindles: Measurement and Evaluation Using Multi-Zones Error Map

The rotating performance of motorized spindles is critical to the dimensional accuracy and surface quality of the parts to be machined. This paper proposes a novel measurement strategy and an evaluation method of spindle's rotating performance, considering the loads imposed on the spindle. To be specific, cutting loads are simplified as a unified function to guide the load simulation, and the load-induced error is eliminated using a position adjustment procedure. In a certain speed-load combination, the spindle's rotating performance under the unified load function is measured using a data envelope method. To extend the assessment to all typical work conditions, an evaluation scheme for different speed and load combinations is proposed based on a visual ideal of Multi-Zones Error Map (MZE Map). The necessity of considering the load-dependent rotating performance is demonstrated via several tests conducted on proposed load simulation platform. Besides, the procedures for developing the MZE Map are performed, and the results express an overview relationship between rotating performance and different speed-load conditions. The proposed method provides a new approach to evaluate the rotating performance considering the actual load conditions. This load-dependent oriented evaluating strategy contributes to a more precise health evaluation and management method for motorized spindles in actual machining process.