Analysis of spindle bearing load with regard to the false brinelling effect caused by machine hammer peening

  • R. Mannens
  • D. Trauth
  • J. Falker
  • C. Brecher
  • F. Klocke
ORIGINAL ARTICLE
  • 43 Downloads

Abstract

Machine hammer peening (MHP) is a high-frequency incremental forming process for surface treatment, which is used on milling machines. Because of the stationary motor spindle as a result of the pneumatic and electrical connections to the hammer head, point loads can occur and may initiate false brinelling wear on the spindle bearing rings. The aim of this work is an experimental and numerical analysis of the interdependencies between MHP reaction forces on the spindle adapter and bearings as well as the associated false brinelling wear of the spindle bearing rings during MHP. Firstly, MHP reaction force measurements on a servo-mechanical press with high stiffness with variation of frequency, electrical power, and time were conducted. Secondly, the spindle bearing wear during MHP was analyzed using fatigue tests and complementary simulations by means of numerical FE-software Abaqus 6.14 and software NewSpilad and WinLager. Thirdly, the effect of damaged spindle bearings on the milling operation was analyzed by means of an endurance test system for bearings. The results showed that false brinelling wear on spindle bearing rings occurs at frequencies around fmhp = 100 Hz and maximum reaction forces of Fcompr. = 3,450 N during MHP on milling machines. Furthermore, a significant raise in temperature of the damaged spindle bearing from Tinitial = 25 °C to Tfinal > 80 °C during fatigue test using 5.76 × 106 load cycles could be detected. Thus, a damaged spindle bearing is not suitable for application in permanent operation. However, at frequencies around fmhp = 200 Hz, no false brinelling wear could be detected and the temperature did not raise significantly during fatigue test. Therefore, this undamaged spindle bearing can be used without impairment for permanent operation.

Keywords

Machine hammer Peening Bearing False brinelling Wear 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

References

  1. 1.
    Steitz M, Weigel K, Weber M, Scheil J, Müller C (2013) Coating of deep rolled and hammer peened deep drawing tools. Adv Mater Res 769:245–252CrossRefGoogle Scholar
  2. 2.
    Trauth D (2016) Tribology of machine hammer peened surfaces for deep drawing. Ph.D. thesis, AachenGoogle Scholar
  3. 3.
    Brinksmeier E, Garbrecht M, Meyer D (2008) Surface hardening by strain induced martensitic transformation. Prod Eng-Res Dev 2(2):109–116CrossRefGoogle Scholar
  4. 4.
    Schulze V, Bleicher F, Groche P, Guo YB, Pyun YS (2016) Surface modification by machine hammer peening and burnishing. CIRP Ann Manuf Technol 65:809–832CrossRefGoogle Scholar
  5. 5.
    Steitz M (2016) Tribologisch günstige Oberflächenstrukturierung von Tiefziehwerkzeugen mittels maschinellem Oberflächenhämmern. Ph.D. thesis, DarmstadtGoogle Scholar
  6. 6.
    Klocke F, Trauth D, Schongen F, Shirobokov A (2014) Analysis of friction between stainless steel sheets and machine hammer peened structured tool surfaces: Experimental and numerical investigation of the lubricated interacted gap. Prod Eng-Res Dev 8(3):263–272CrossRefGoogle Scholar
  7. 7.
    Bleicher F, Lechner C, Habersohn C, Obermair M, Heindl F, Rodriguez Ripoll M (2013) Improving the tribological characteristics of tool and mould surfaces by machine hammer peening. CIRP Ann Manuf Technol 62:239–242CrossRefGoogle Scholar
  8. 8.
    Lynagh N, Rahnejat H, Ebrahimi M, Aini R (2000) Bearing induced vibration in precision speed routing spindles. Int J Mach Tool Manu 40:561–577CrossRefGoogle Scholar
  9. 9.
    Upadhyay RK, Kumaraswamidhas LA, Sikandar Azam MD (2013) Rolling element bearing failure analysis: a case study. In: Case studies in engineering failure analysis, vol 1, pp 15–17Google Scholar
  10. 10.
    Schadow C (2016) Stillstehende fettgeschmierte Wälzlager unter dynamischer Beanspruchung. Ph.D. thesis, MagdeburgGoogle Scholar
  11. 11.
    Weck M, Brecher C, Schulz A, Keiser R (2003) Stabilitätsanalyse bei der HSC-Bearbeitung. wt Werkstattstechnik Online 93:63–98Google Scholar
  12. 12.
    Hertz H (1881) ÜBer die berührung fester elastischer körper. Journal für die reine und angewandte Mathematik, BerlinGoogle Scholar
  13. 13.
    Sommer K, Heinz R, Schöfer J (2010) Verschleiß metallischer Werkstoffe: Erscheinungsformen sicher beurteilen. Vieweg + Teubner Verlag, Wiesbaden, pp 122–369CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2018

Authors and Affiliations

  1. 1.Laboratory for Machine Tools & Production Engineering WZLRWTH Aachen UniversityAachenGermany

Personalised recommendations