Energy consumed by a bearing supported spindle in the presence of a dynamic cutting force and of defects

A machine tool spindle system model is proposed in this paper to investigate the non-linear face-milling cutting forces behavior, which are neglected in the literature, in order to predict the total mechanical power of a spindle. A simulation of the structure of the spindle based on the finite-element method is elaborated to estimate the variable cutting forces and then the variable power loss generated by bearings, considering the angular position and contact angles of the variable balls. Experiments are elaborated to compare the experimental power values with the predicted results. Particular attention is paid to different types of defects (inner ring spalling, outer ring spalling, eccentricity, and unbalance) in order to study their impact on the power consumed by the spindle during the approach and cutting phases under different rotating conditions.