An Analysis Model to Predict Rotation Accuracy of High-Precision Spindles Considering Part Errors and Deformation

High-precision spindles have significant influence on the machining precision and finishing quality largely due to their motion errors. However, the analysis of rotation accuracy is quite not easy in design stage because of the neglecting of geometric errors and deformations of parts in the traditional dimension chains. Hence, a theoretical analysis model is built in present study to do the prediction. The 3D error accumulation path is recognized by Datum Flow Chain (DFC) and the key tolerances are modeled by Small Displacement Torsor (SDT). Thereafter, the variation propagation is conducted by Homogeneous Transformation Matrices (HTM) and the geometric misalignment in the spindle is calculated. Then, an FEA model is built with Timoshenko beam elements and the deformation is calculated after the geometric misalignment is applied to the model. As spindle rotates, the trajectory of the spindle nose is obtained. Finally, the Monte Carlo (MC) method is used to get the distribution and the range of motion errors. To verify the feasibility and reliability of the analysis model, the radial and axial motion errors of a double supported high-precision spindle are analyzed.