Design of an energy saving oil cooler system using hot gas

According to the development of machine tools to higher speed and multi axes, thermal error which is known to account for about 70% of the total error of machine tools is becoming a serious issue. To reduce thermal error, the heat generating parts of machine tools are cooled down by direct contact with a cooling medium. The medium in most cases is oil, thus, the cooling device is called oil cooler. In this study, an oil cooler system employing hot gas bypass method was developed to improve the performance including energy efficiency of the oil coolers used for ultra-precision machine tools. Through tests, the developed system exhibited high temperature control accuracy of ±0.1°C, and less energy consumption than conventional on/off type (equipped with heater for preventing excessive cooling) by about 45%. The proposed oil cooler system is applicable to semiconductor process, ultra-precision injection molds, as well as ultra-precision machine tools to improve product quality and energy efficiency of production facilities.     

Comparison of system performance on hot-gas bypass and variable speed compressor in an oil cooler for machine tools

This paper compares the system performance for two representative capacity control schemes, hot-gas bypass and variable speed compressor in an oil cooler for machine tools. An empirical linear first-order model of each controlled system was obtained from experiments by imposing a stepwise control signal to each actuator of the system. General proportional-integral controllers are designed based on the empirical transfer function models in order to control the target temperature of the oil cooler system. The experiments of starting and thermal load change were conducted to compare their control performance with each other. Especially, coefficient of performance (COP) of the two control schemes under the partial load state was also analyzed in detail. From the analyses of experimental results, the control performance of the target temperature in the two control schemes had almost the same control accuracy of ±0.1 °C at steady state. However, the COP of a variable speed compressor was as many as five-times greater than that of hot-gas bypass in comparable minimum partial load state of 0.5 kW.     

Thermal error reduction based on thermodynamics structure optimization method for an ultra-precision machine tool

Thermal error is one of the main errors in ultra-precision machine tools. This paper presents a thermodynamics-based structure optimization method to reduce the thermal displacements of machine tools during operation. The method makes use of the thermal–structure coupled model to analyze the thermal behavior considering the thermal contact resistance and the temperature rise of the oil film in hydrostatic spindle. The structure of the motor link, spindle, and headstock of grinder are optimized by setting appropriate gaps in the contact region of two neighboring parts to change the heat transfer distribution and minimize the thermal displacement of the spindle center position. The proposed method is validated by an equivalent thermal conductivity-based simulation method and experiment on an ultra-precision grinding machine tool. Experimental results show that the proposed method can provide an important instruction on how to reduce the thermal error for the design of the precision machine tools, especially for those with key parts placed near the heat sources.     

超精密环境温度控制及温度测量技术研究

分析在超精密加工环境中进行高精度温度测量与控制的原理及方法。在分层次逐步实现的原则下,依据传热学原理,规则并初步建成了一个超精密的加工环境。     

Performance investigation of capillary tubes for machine tool coolers retrofitted with HFC-407C refrigerant

The machine tool coolers are the best managers of coolant temperature in avoiding the deviation of spindle centerline for machine tools. However, the machine coolers are facing the compressed schedule to phase out the HCFC (hydro-chloro-floro-carbon) refrigerant and little attention has been paid to comparative study on sizing capillary tube for retrofitted HFC (hydro-floro-carbon) refrigerant. In this paper, the adiabatic flow in capillary tube is analyzed and modeled for retrofitting of HFC-407C refrigerant in a machine tool cooler system. A computer code including determining the length of sub-cooled flow region and the two phase region of capillary tube is developed. Comparative study of HCFC-22 and HFC-407C in a capillary tube is derived and conducted to simplify the traditional trial-and-error method of predicting the length of capillary tubes. Besides, experimental investigation is carried out by field tests to verify the simulation model and cooling performance of the machine tool cooler system. The results from the experiments reveal that the numerical model provides an effective approach to determine the performance data of capillary tube specific for retrofitting a HFC-407C machine tool cooler. The developed machine tool cooler system is not only directly compatible with new HFC-407C refrigerant, but can also perform a cost-effective temperature control specific for industrial machines.     

Experimental Investigation of Capacity Control Scheme on System Performance for a Machine Tool Cooler

Highly accurate manufacture in machining industry can only be obtained with precise temperature control of the coolant (oil or water).Machine tool with more accurate,stable and advanced the precision of the working component cannot be developed without appropriate cooling.However,the machine tool coolers are facing the control hunting of cooling temperature and the dramatic variation of heat load in high-accuracy machining.The main objective of this study is to evaluate the influence of the hot-gas by-pass scheme and suction regulation for capacity control of a machine tool cooler system.In this study,experimental investigation on both hot-gas by-pass scheme and suction valve regulation for capacity control has been proposed.Effects of using capillary tube and thermostatic expansion valve along with different capacity control scheme have been investigated extensively in an environmental testing room.Cooling performance and power consumption of the cooler system have been measured and analyzed as well by comparing with different opening percentage of throttling valve under specific coolant temperature.The experimental results reveal that the power consumption will reduce slightly by capacity control using the hot-gas by-pass scheme but the coefficient of performance (COP) of the overall system will decrease.Lower coolant temperature will result in higher compressor power consumption as well.While conducting suction valve regulating for capacity control,energy-saving at 10%-12% can be obtained by using thermostatic expansion valve under different evaporator load.It also reveals that suction valve regulation along with adequate choice of thermostatic expansion valve can provide alternative choice for steady capacity control and substantial energy-saving.The proposed cooler systems with different capacity control schemes are not only more cost-effective than inverter driven system,but also can perform energy-saving and precise temperature control specific for high-accuracy machine tool cooling.     

Design of a five-axis ultra-precision micro-milling machine—UltraMill. Part 2: integrated dynamic modelling, design optimisation and analysis

Using computer models to predict the dynamic performance of ultra-precision machine tools can help manufacturers to substantially reduce the lead time and cost of developing new machines. However, the use of electronic drives on such machines is becoming widespread, the machine dynamic performance depending not only on the mechanical structure and components but also on the control system and electronic drives. Bench-top ultra-precision machine tools are highly desirable for the micro-manufacturing of high-accuracy micro-mechanical components. However, the development is still at the nascent stage and hence lacks standardised guidelines. Part 2 of this two-part paper proposes an integrated approach, which permits analysis and optimisation of the entire machine dynamic performance at the early design stage. Based on the proposed approach, the modelling and simulation process of a novel five-axis bench-top ultra-precision micro-milling machine tool—UltraMill—is presented. The modelling and simulation cover the dynamics of the machine structure, the moving components, the control system and the machining process and are used to predict the entire machine performance of two typical configurations.     

A strategy for minimization of thermal error in headstock assembly of CNC lathe

The thermo-elastic behavior of the spindle system in a CNC lathe contributes significantly toward the undesirable displacement at the tool center point (TCP). Minimization of the thermal deformation of spindle has become progressively important for the development of ultra-precision machine tools. To serve the purpose of predicting the characteristics of the heat flow and the corresponding thermal deformation, a finite element model for the headstock assembly of CNC lathe is developed. Heat generation and heat dissipation in the components of headstock assembly of CNC lathe are estimated for free running as well as machining conditions using empirical models. The thermo-elastic behavior is investigated with the aid of numerical model validated by experimentation. The deformation of bed is found to possess a significant influence toward the spindle displacement in X-axis which results in form error in the machined component. The proposed strategy is validated effectively to have control over the heat flow between headstock and bed with the aid of a carbon/epoxy laminate that results in a near zero displacement along the X-axis of the spindle.     

Theory analysis and system identification methods on thermal dynamics characteristics of ballscrews

Empirical model of machine tools on thermal error has been widely researched, which can compensate for thermal error to some extent but not suitable for thermal dynamic errors produced by dynamic heat sources. The thermoelastic phenomenon of unidimensional heat transfer of ballscrews influenced by changeable heat sources is analyzed based on the theory of heat transfer. Two methods for system identification (the least square system identification and BP artificial neural network (ANN) system identification) are put forward to establish a dynamic characteristic model of thermal deformation of ballscrews. The model of thermal error of the X axis in a feed system of DM4600 vertical miller is established with a fine identification effect. Comparing the results of the two identification methods, the BP ANN system identification is more precise than the least square system identification.     

数控机床主轴热变形伪滞后研究及主轴热漂移在机实时补偿

为研究数控机床热变形规律,实现数控机床误差在机实时补偿,进行数控机床主轴热变形理论及试验分析,结果表明,数控机床主轴热变形与主轴温变在距热源约1/3位置存在近似线性关系,即主轴热变形存在伪滞后现象,这一结果为数控机床测温点优化布置及热误差鲁棒建模提供理论依据。为验证机床热变形伪滞后现象,对VM850加工中心主轴热漂移误差在机实时检测并建模,通过自主研发数控机床误差在线实时补偿系统对主轴热漂移误差进行实时补偿,经补偿,机床主轴热漂移误差减少90%以上,有效提高了数控机床主轴精度。     

Suppression of thermal deformation of machine tool spindle using TiC-Fe composite

The minimization of error generation in machine tool spindle is important because high-speed and ultra-precision machining are extensively utilized in industrial fields. The thermal deformation of the machine tool spindle generated by the frictional heat between the outer and inner bearings can deteriorate the machining accuracy. In this study, a TiC−SUS431 composite was fabricated using the liquid pressing infiltration method to suppress thermal deformation, and its thermal properties were obtained by thermal characteristic tests. For the transient thermal analysis with finite element analysis, the parameters of the machine tool spindle-bearing model were selected, and the boundary conditions were calculated. The temperature and thermal deformation of the analysis model were compared by applying SCM415 and TiC−SUS431 to the material of the machine tool spindle and changing the rotation speed. From the analysis results, it was demonstrated that the TiC−SUS431 machine tool spindle can improve the machining accuracy by minimizing the spindle thermal deformation.

     

Theory analysis and system identification methods on thermal dynamics characteristics of ballscrews

Empirical model of machine tools on thermal error has been widely researched, which can compensate for thermal error to some extent but not suitable for thermal dynamic errors produced by dynamic heat sources. The thermoelastic phenomenon of unidimensional heat transfer of ballscrews influenced by changeable heat sources is analyzed based on the theory of heat transfer. Two methods for system identification (the least square system identification and BP artificial neural network (ANN) system identification) are put forward to establish a dynamic characteristic model of thermal deformation of ballscrews. The model of thermal error of the X axis in a feed system of DM4600 vertical miller is established with a fine identification effect. Comparing the results of the two identification methods, the BP ANN system identification is more precise than the least square system identification.     

Thermal influence of the Couette flow in a hydrostatic spindle on the machining precision

Hydrostatic spindles are increasingly used in precision machine tools. Thermal error is the key factor affecting the machining accuracy of the spindle, and research has focused on spindle thermal errors through examination of the influence of the temperature distribution, thermal deformation and spindle mode. However, seldom has any research investigated the thermal effects of the associated Couette flow. To study the heat transfer mechanism in spindle systems, the criterion of the heat transfer direction according to the temperature distribution of the Couette flow at different temperatures is deduced. The method is able to deal accurately with the significant phenomena occurring at every place where thermal energy flowed in such a spindle system. The variation of the motion error induced by thermal effects on a machine work-table during machining is predicated by establishing the thermo-mechanical error model of the hydrostatic spindle for a high precision machine tool. The flow state and thermal behavior of a hydrostatic spindle is analyzed with the evaluated heat power and the coefficients of the convective heat transfer over outer surface of the spindle are calculated, and the thermal influence on the oil film stiffness is evaluated. Thermal drift of the spindle nose is measured with an inductance micrometer, the thermal deformation data 1.35 μm after running for 4 h is consistent with the value predicted by the finite element analysis's simulated result 1.28 μm, and this demonstrates that the simulation method is feasible. The thermal effects on the processing accuracy from the flow characteristics of the fluid inside the spindle are analyzed for the first time.     

Thermometric design considerations for temperature monitoring in machine tools and CMM structures

Temperature measurement is an essential element in monitoring and studying the thermal deformation response of machine tools and CMM structures. In this context, temperature measurement is required for model verification, for control purposes and for determining the thermal contact resistance and other thermal boundary conditions. In these applications, where heat flux and temperature rise levels are relatively low, a proper thermometric design is a must to ensure accurate and precise results. This paper addresses the problem of thermometric design in the case of temperature measurement inside a solid body and on its surface. Results and recommendations regarding the interactions between neighbouring thermocouples, the effect of the distance between the thermocouple and the contact interface (i.e. the heat input surface), and the effect of heat flow along the thermocouple wires on the measurement error are presented. The issue of the effect of the unknown thickness and thermal conductivity of the surface paint on the uncertainty in surface temperature measurement is also addressed.     

Actualities and Development of Heavy-Duty CNC Machine Tool Thermal Error Monitoring Technology

Thermal error monitoring technology is the key technological support to solve the thermal error problem of heavy-duty CNC(computer numerical control) machine tools. Currently, there are many review literatures introducing the thermal error research of CNC machine tools,but those mainly focus on the thermal issues in small and medium-sized CNC machine tools and seldom introduce thermal error monitoring technologies. This paper gives an overview of the research on the thermal error of CNC machine tools and emphasizes the study of thermal error of the heavy-duty CNC machine tool in three areas. These areas are the causes of thermal error of heavy-duty CNC machine tool and the issues with the temperature monitoring technology and thermal deformation monitoring technology. A new optical measurement technology called the ‘‘fiber Bragg grating(FBG) distributed sensing technology' for heavy-duty CNC machine tools is introduced in detail. This technology forms an intelligent sensing and monitoring system for heavy-duty CNC machine tools.This paper fills in the blank of this kind of review articlesto guide the development of this industry field and opens up new areas of research on the heavy-duty CNC machine tool thermal error.     

车用发动机润滑油冷却器传热和阻力特性的研究

选取国内生产车用发动机润滑油冷却器的4个主要厂家生产的同一型号的8个冷却器进行了传热和阻力特性的实验研究,实验结果表明,由于采用不同生产工艺,冷却器的传热性能和阻力特性有较大的差异。根据冷却器传热性能和阻力特性的实验数据拟合了换热量、阻力随润滑油流量的变化关系,可为车用润滑油冷却器的结构设计及选型提供依据。     

基于接触热阻的磨齿机电主轴热特性分析

大规格数控成形磨齿机高速电主轴系统在加工过程中产生大量热量,导致砂轮主轴产生相应热变形,影响加工精度。针对这一现象,提出了一种考虑接触热阻的瞬态热-结构耦合分析方法。该方法基于分形理论,利用W-M分形函数表征结合面接触状态,使用均方根测度法对分形参数进行识别。结合基体热阻和收缩热阻的影响计算结合面间总接触热阻,并计算热源发热量及各部件的对流换热系数,建立了综合考虑内部热源、边界条件和接触热阻的综合有限元模型,获得热误差仿真结果。分析电主轴温度及热变形在是否考虑接触热阻情况下变化差异。最后建立电主轴系统热误差测量试验平台,通过试验验证了该方法的准确性和可靠性。通过仿真得到温度及热位移量与实验值基本一致。     

Thermal error characteristic analysis and modeling for machine tools due to time-varying environmental temperature

The accuracy of machine tools is affected by both internal heat sources and time-varying environmental temperature. Therefore, the thermal deformation caused by environmental temperature variation is an important factor, which requires attention during thermal error modeling. In order to analyze the influence of time-varying environmental temperature on the thermal error of the machine tool, this paper proposed a thermal error modeling approach by using the thermal error transfer function of the machine tool. The approach was implemented in the following three steps. First, the thermal time constant of major components was calculated, according to structural parameters. Then, the thermal error transfer function of the components was derived. Finally, the thermal error transfer function of the whole machine was built based on the construction relationship. The analytical approaches of time domain and frequency domain were applied to obtain the thermal characteristics of machine tools based on the thermal error transfer function. Numerical simulations and the Z-axis operating experiment of three-axis milling machine were performed to verify the accuracy and effectiveness of the thermal error predicted model. The result shows that the proposed model is versatile and general with a clear modeling mechanism, which would provide a useful tool for the analysis and optimization design of machine tools with good thermal robustness.     

数控机床主轴-立柱系统热态特性分析与测试

针对数控机床主轴-立柱系统因受热变形而影响机床加工精度的问题,本文基于能量守恒定律建立了主轴-立柱系统耦合分析模型来获取其热态特性。该模型综合考虑了热源计算、传热系数计算、结构约束以及散热面放置情况等因素,并采用风速法来获取主轴与空气间的传热系数。为了验证主轴-立柱系统耦合分析模型的有效性,本文设计并搭建了数控机床热态特性试验平台,以具体数控机床为研究对象获得了其主轴-立柱系统的温度场分布、热变形以及热平衡时间等热态特性。试验结果表明:各测点数据中温度的最长绝对误差和最大相对误差分别为0.71℃,2.94%,出现在主轴体的测点处,热变形的绝对误差和相对误差分别为1.49μm,8.71%,采用风速法建立的主轴-立柱系统耦合分析模型所获得的热态特性与试验获得的结果基本一致。本文的研究成果为数控机床减少热误差,提高精度保持性提供了参考。     

基于CNN-GRU组合神经网络的数控机床进给系统热误差研究

热变形引起的误差是影响数控机床精度的主要因素之一。为了减小热误差对数控机床精度的影响,提出一种基于CNN-GRU组合神经网络的热误差预测方法。通过热误差实验,采集螺旋曲面专用数控机床直线进给系统的温升数据和热误差数据;利用模糊C均值聚类和灰色关联度分析筛选进给系统温度敏感点;以温度敏感点的温升数据和进给系统热误差为数据样本,建立CNN-GRU热误差预测模型。为验证模型的准确性和实用性,与基于CNN-LSTM和基于LSTM的传统热误差预测模型进行预测对比分析,结果表明CNN-GRU模型预测结果的平均绝对误差、均方根误差和决定系数均优于CNN-LSTM模型和LSTM模型,具有较高的预测精度和鲁棒性。提供的热误差模型可为后续误差补偿奠定基础,为数控机床的热误差预测提供思路。