Thrust-Bearing Layout Design of a Large-Sized Hydrostatic Rotary Table to Withstand Eccentric Loads for Horizontal Boring Machine Applications
Abstract
:1. Introduction
2. Model and Research Method
2.1. Introduction to the Research Model
2.1.1. Structural Analysis of the Model
- Layout I: A single-ring recess layout that uses the minimum-diameter recess; the diameter (ø) is 1059 mm, and the internal diameter of the recess (R1) is aligned with the internal diameter of the connector.
- Layout II: A single-ring recess layout that uses the maximum-diameter recess; the diameter (ø) is 1228 mm, and the external diameter of the recess (R4) is aligned with the external diameter of the connector.
- Layout III: A dual-ring recess layout in which the positions of the minimum-diameter recess and the maximum-diameter recess are staggered.
2.1.2. Recess Flow Field Model
2.1.3. Verification of Flow Field Model
2.2. Boundary Conditions of Stimulation
- In the steady-state thermal and the static-structural models, the air-side natural convection temperature of the hydrostatic rotary table model was specified at 27 °C. Since this study only took into account the effects of oil film temperature rise on the hydrostatic rotary table, the simulated temperature rise distribution results of the original and the three new hydrostatic axial thrust bearing designs (as obtained through ANSYS FLUENT software) were jointly incorporated into a structural heat-transfer model in order to perform one-way fluid-solid interactions. The simulated oil film temperature rise distribution results at a maximum rotational speed of 15 rpm were applied to the hydrostatic axial thrust bearing and the hydrostatic journal bearing, while the results at a maximum feed speed of 2 m/min were applied to all recesses in the closed-type hydrostatic slideway.
- This study utilized the Joint_Type_Bushing structural model tool to simulate the oil film stiffness of all recesses at the initial oil film thickness. The initial oil film thickness of the recess served as the initial spacing between the structural models simulated through Joint_Type_Bushing. As shown in Figure 12a, the model spacing between the connector and the hydrostatic axial thrust bearing recess was 50 μm; the model spacing between the hydrostatic journal bearing recess and the connector was 50 μm. As shown in Figure 12b, the model spacing between the main and vice recesses and the fixed guide rail was 50 μm; the model spacing between the side recess and the fixed guide rail was 50 μm.
- The contact conditions of the gear connector and the small gears in the gearbox are shown in Figure 13. The frictional contact type was selected here. The contact between the clamp and the gear connector was frictional, as shown in Figure 14. The contact condition between the ball screw and the fixed guide rail was bonded, as shown in Figure 15.
- The maximum external load utilized in this study consisted of the maximum axial workpiece weight of 117,682 N and the maximum axial specific drilling force of 9348 N.
3. Analysis Results
3.1. Simulation Results of the Oil Film Temperature Field of Different Hydrostatic Thrust Bearing Layouts
3.2. Simulation Results of the Thermal Deformation of Worktable from Different Hydrostatic Thrust Bearing Layouts
3.3. Simulation Results of the Structural Deformation of the Worktable Caused by an Evenly Distributed Load
3.4. Simulation Results of the Structural Deformation of the Worktable Caused by an Eccentric Load
4. Analysis Results and Discussion
- Under the evenly distributed load and eccentric load conditions, Layout III had the smallest worktable deformation among the four layouts, while Layout I had the largest deformation under both conditions. These results show that the larger the recess layout diameter, the greater the recess’s resistance against the tilting moment, which reduced the structural deformation of the worktable.
- The thermal deformation caused by Layout II was the largest among the four layouts, while Layout I had the smallest thermal deformation.
- When the rotational speed of the rotary table was fixed, a hydrostatic thrust bearing recess placed farther away from the center of the worktable would experience a faster tangential speed, which increased the oil film temperature.
5. Conclusions
- The layout diameter of the hydrostatic thrust bearing recess has a significant effect on the worktable’s resistance against an eccentric load. A dual-ring recess layout offers better resistance against the tilting moment compared to a single-ring layout while, in single-ring layouts, a larger layout diameter offers better resistance against the tilting moment compared to a smaller layout diameter.
- If one chooses a recess layout based on the rotary table’s resistance against the tilting moment, the oil film temperature must also be taken into account, due to the reduced recess dimensions in a limited structural space. Moreover, the recess of a hydrostatic thrust bearing placed further away from the center of the worktable experiences a faster tangential speed, which increases the oil film temperature. In Layout II, eight recesses were placed within the range of the maximum layout diameter, which resulted in the largest thermal deformation of the worktable; in Layout III, only four recesses were placed within that range, which caused a medium thermal deformation; in Layout I, the minimum layout diameter was used, which resulted in the smallest thermal deformation.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
Nomenclature
Ae | effective area of recess | Ps | supply pressure |
B | width of bearing pad | Pr | recess pressure |
b | width of recess | Qc0 | flow rate of capillary at designed film gap |
b1 | sill of bearing pad in width direction | Qh0 | outlet flow rate of bearing sills designed film gap |
dc | inner diameter of capillary | Qoutlet | outlet flow rate of the recess |
e | eccentricity | Qinlet | inlet flow rate of the recess |
ε | eccentricity rate | q1,2,3,4 | flow rate at sill 1, 2, 3, 4 |
h0 | designed film gap | R1 | inner radius of the bearing pad |
L | length of bearing pad | R2 | inner radius of the recess |
l | length of recess | R3 | outer radius of the recess |
l1 | sill of bearing pad in length direction | R4 | outer radius of the bearing pad |
lc | length of capillary | Rc | flow resistance of the capillary |
θ | angle of the recess | Rc0 | flow resistance of the capillary at designed film gap |
μt | viscosity of the lubricant oil | Rho | flow resistance of the bearing sills at designed film gap |
W | Load-carrying capacity of the bearing pad |
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Size Position | Thrust Oil Recess |
---|---|
θ (deg) | 35 |
R1 (mm) | 371 |
R2 (mm) | 404 |
R3 (mm) | 544 |
R4 (mm) | 577 |
Effective area (m2) | 0.045 |
Recess depth (mm) | 2 |
Dimension | Recess of Maximum Diameter | Recess of Minimum Diameter |
---|---|---|
θ (deg) | 35 | 35 |
R1 (mm) | 459.5 | 371 |
R2 (mm) | 492.5 | 404 |
R3 (mm) | 581 | 515.85 |
R4 (mm) | 614 | 548.85 |
Effective area (m2) | 0.03619 | 0.03619 |
Recess depth (mm) | 2 | 2 |
Outlet Flow Rate | |
---|---|
Min. diameter recess | 1.290 × 10−5 m3/s |
Max. diameter recess | 1.460 × 10−5 m3/s |
Original recess | 1.106 × 10−5 m3/s |
Max Oil Film Temperature | |
---|---|
Min diameter recess | 29.97 °C |
Max diameter recess | 30.58 °C |
Original oil recess | 30.02 °C |
Layout | Layout I Deformation (mm) | Layout II Deformation (mm) | Layout III Deformation (mm) | ||||
---|---|---|---|---|---|---|---|
Eccen. Load | |||||||
Zone | Min | Max | Min | Max | Min | Max | |
A | 0.0034 | −0.148 | 0.0015 | −0.138 | 0.0015 | −0.139 | |
B | 0.0036 | −0.148 | 0.0018 | −0.138 | 0.0018 | −0.139 | |
C | 0.0037 | −0.150 | 0.0014 | −0.142 | 0.0014 | −0.141 | |
D | 0.0035 | −0.148 | 0.0012 | −0.139 | 0.0012 | −0.140 |
Maximum Deformation | |
---|---|
Layout I | −0.150 mm |
Layout II | −0.142 mm |
Layout III | −0.141 mm |
Original layout | −0.145 mm |
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Huang, H.-C.; Yang, S.-H. Thrust-Bearing Layout Design of a Large-Sized Hydrostatic Rotary Table to Withstand Eccentric Loads for Horizontal Boring Machine Applications. Lubricants 2022, 10, 49. https://doi.org/10.3390/lubricants10040049
Huang H-C, Yang S-H. Thrust-Bearing Layout Design of a Large-Sized Hydrostatic Rotary Table to Withstand Eccentric Loads for Horizontal Boring Machine Applications. Lubricants. 2022; 10(4):49. https://doi.org/10.3390/lubricants10040049
Chicago/Turabian StyleHuang, Hua-Chih, and Shen-Hen Yang. 2022. "Thrust-Bearing Layout Design of a Large-Sized Hydrostatic Rotary Table to Withstand Eccentric Loads for Horizontal Boring Machine Applications" Lubricants 10, no. 4: 49. https://doi.org/10.3390/lubricants10040049
APA StyleHuang, H. -C., & Yang, S. -H. (2022). Thrust-Bearing Layout Design of a Large-Sized Hydrostatic Rotary Table to Withstand Eccentric Loads for Horizontal Boring Machine Applications. Lubricants, 10(4), 49. https://doi.org/10.3390/lubricants10040049