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Fig 772: Bearing systems for precision machines [37]
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Gas Lubricated Bearings
Table 77 describes the different properties sought for various spindle systems Rolling elements due to their surface-to-surface contact suffer from a lot of drawbacks such as a thermal growth in the process, wear stabilization time and other errors, whereas aerostatic and hydrodynamic bearings are superior in these characteristics Rolling element bearings are better in terms of axial and radial stiffness and also the load carrying capacity for which aerostatic and hydrodynamic bearing are lagging However, due to the many drawbacks, rolling element bearings are less commonly used in ultra-precision machines Both Figure 772 and Table 77 prepared by Weck [37] give a very good insight into the strength and the weakness of each type of bearing together with the applications Figure 773 shows the dimensions of aerostatic, hydrodynamic and ball bearings required for a radial stiffness of about 70,000 N/mm (400,000 lbf/in2) and a maximum radial load capacity of 6675 N (150 lbf) In this comparison, it is assumed that the maximum permissible outer diameter is 100 mm (4 in), whereas the shaft diameter is at least 38 mm (15 in) The comparison can now be made for several parameters such as load capacity, radial stiffness, total power consumption, axis definition and wear Table 77 Properties of different spindle systems for precision applications [37]
Aerostatic spindle system Hydrostatic spindle system Rolling element spindle system
Characteristics of spindle systems for high and ultraprecise applications Asynchronous error motion Total error motion Load capacity Wear Radial static stiffness Axial static stiffness Dynamic behaviour Thermal growth Stabilization time : very short Spindle speed Price/cost
very good
poor
Precision Engineering
Fig 773: Comparison of bearing types [3]
Gas Lubricated Bearings
In general, by referring to Table 78, the load capacity of the hydrodynamic bearing is closely related to the operating temperature Usually, hydrodynamic bearings are not used for high-speed applications because of the excessive power consumption and heating The maximum radial load of the ball bearings seems to decrease with an increase in speed On the other hand, the load capacity of the aerostatic bearing increases with higher speeds due to an aerodynamic effect Table 78 Comparison of bearing types load capacity modified to include stiffness [3]
Maximum radial load (lbf) at 3,000 rpm at 20,000 rpm 95 1,050 5,000 (40 C) 1,900 120 600 Radial static stiffness
Bearing type
Aerostatic (e = 05) Ball bearing Hydrodynamic Hydrostatic (e = 05)
very good
poor
The radial stiffness of a journal bearing depends on the stiffness of the shaft, the bearing bush, the quill body and the support structure In addition, for the hydrodynamic bearing, this also depends on the lubricant film A practical stiffness value between 875 and 175 N/ m (500,000 and 1,000,000 lbf/in) is possible for quill assemblies employing hydrodynamic bearings On the other hand, ball bearings and aerostatic bearings are capable of exhibiting stiffness between 4375 and 875 N/ m (250,000 and 500,000 lbf/in) It is also noted that ball bearings allow for a larger shaft diameter for a better rigidity In general, by referring to Table 79, it is seen that the power consumption for the aerostatic bearing is the lowest because of the low value of friction torque in the gas film This also indicates that very little heat is generated and that thermal distortion is seldom a problem The power consumption due to the compressor should also be considered for the aerostatic bearing However, with inclusion, the total power consumed is still relatively lower than that of the hydrodynamic bearings Ball bearings consume the least total power at low speeds because they are independent of any external lubrication and cooling However, at elevated speeds, friction heat is produced during the operation and the total is even higher than the total combined power consumed by aerostatic bearings
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