Key Takeaways & Executive Findings
- •• Acoustic levitation provides a novel active control method for frequency domain error of aerostatic spindles, addressing a critical limitation in ultra-precision machining. • A multi-field coupling model (acoustic-magnetic-fluid-solid) was developed to simulate the rotor dynamics of the aerostatic spindle, enabling prediction of error control. • Numerical simulations and preliminary experiments confirmed that acoustic levitation can effectively reduce frequency domain errors, validating the proposed method. • This approach offers a promising solution for achieving full-frequency band error control in high-end optical component manufacturing.
Abstract
In the machining of high-end optical components, the aerostatic spindle error of an ultra-precision machine tool has a significant impact on the surface quality of the machined surfaces. The surfaces of many high-end optical components need to meet the extremely stringent requirements of the full-frequency band error, which poses significant challenge to the control of the aerostatic spindle error. In this research, we put forward an active control method for the frequency domain error of the aerostatic spindle based on acoustic levitation, in which the acoustic-magnetism-fluid-solid multi-field coupling rotor dynamics modeling method of the aerostatic spindle was proposed and the corresponding multi-field coupling model was established. Through the numerical simulation and preliminary experiments, the influence law of acoustic levitation on the frequency domain error of the aerostatic spindle is obtained. The results showed that acoustic levitation can be used to control the frequency domain error of the aerostatic spindle to some extent, which verified the effectiveness of the proposed method.
1. Introduction
Ultra-precision machine tools are indispensable for ultra-precision machining and are widely used in the manufacturing of high-end optical components [1, 2]. In the processing of optical elements, the key components of the machine tool (spindle and guide rail) influence the frequency domain error of the machined surface. The guide rail primarily affects the low frequency error and is relatively straightforward to control, while the spindle affects the medium and high frequency error, but is more challenging to actively control. In other words, the control of spindle frequency domain error has become the limiting factor in the full-frequency band error control of optical elements.
The spindle is a pivotal component of ultra-precision machine tools. The frequency domain error of the aerostatic spindle, defined as the frequency and amplitude information of the spindle error motion obtained through frequency domain analysis, exerts a significant influence on the machining surface frequency domain error [3–5]. Combined with the machining process parameters, its frequency domain error significantly affects the frequency domain error of the machined surface of the workpiece [6–8].
To achieve effective control of the frequency domain error associated with high-performance optical components, it is essential to prioritize the resolution of the issue pertaining to the controllability of the frequency domain error associated with the aerostatic spindle. In conventional research, scholars primarily depend on enhancing the spindle’s limit accuracy and process parameter regulation, among other strategies, to attain control over the frequency domain error of the machined surface. However, the research identified several shortcomings and limitations in the optimization design and process parameter regulation of the aerostatic spindle for the realization of high-quality machining surface frequency domain error control. The active control of the aerostatic spindle error necessitates the incorporation of supplementary physical field effects, including the introduction of magnetic levitation and ultrasonic levitation. Nevertheless, the regulation of magnetic levitation forces is a highly intricate process. In the context of ultra-precision machining, the introduction of supplementary magnetic fields has the potential to further exacerbate the imbalance in the magnetic forces exerted by the spindle motor. The ultrasonic levitation bearing technology has a lower load-carrying capacity; however, the bearing has a superior effect on rotor vibration suppression and is relatively straightforward to control actively. This study demonstrates that the combination of ultrasonic levitation bearing technology and aerostatic bearing technology facilitates the active control of spindle frequency domain error while maintaining spindle stability, thereby providing a novel approach to active spindle frequency domain error control.
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Guoda Chen, Zhaoshou Chen, Yifan Ge (2025). Active Control Method for Frequency Domain Error of Aerostatic Spindle Based on Acoustic Levitation. Chinese Journal of Mechanical Engineering. https://doi.org/10.1186/s10033-024-01163-w
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Frequently Asked Questions
What is the main contribution of this paper?
The paper proposes an active control method for the frequency domain error of aerostatic spindles using acoustic levitation, including a multi-field coupling model and experimental validation.
How does acoustic levitation help in controlling spindle error?
Acoustic levitation introduces an additional physical field that can suppress rotor vibrations, thereby reducing the frequency domain error of the spindle without compromising stability.
What is the significance of the multi-field coupling model?
The model integrates acoustic, magnetic, fluid, and solid interactions to accurately simulate the rotor dynamics, enabling prediction and optimization of the control method.
What are the potential applications of this research?
This research can be applied in ultra-precision machine tools for manufacturing high-end optical components, where stringent full-frequency band error control is required.
What are the limitations of the proposed method?
The method is still in preliminary stages; further research is needed to optimize acoustic levitation parameters and integrate it into practical machining systems.
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