Investigation of the effects of spindle unbalance induced error motion on machining accuracy in ultra-precision diamond turning

• Eccentricity error motion has significant effect on machining accuracy.
• A dynamics model is proposed to analyze the dynamics behavior of aerostatic bearing spindle (ABS).
• Double high frequency vibration generates a low frequency enveloping phenomenon.
• The distance between the spindle axis and the tool tip varies due to the hydrodynamic effect of ABS.

In ultra-precision machining, error motions of the aerostatic bearing spindle (ABS) have significant effects on the machining accuracy. Spindle unbalance is a critical factor attributing to error motions of the ABS. Much work currently has been focused on the measurement of error motions and spindle balancing. However, the unbalance induced spindle error motion (UISEM) and the corresponding effects on machining accuracy are not well understood. In this paper, a dynamics model of the ABS was established to characterize the UISEM and its dynamic behavior with consideration of the unbalance effects. A series of groove turning experiments were especially designed to investigate the UISEM. Good agreement between theoretical and experimental results was achieved, demonstrating the low frequency enveloping phenomenon of the error motions of the ABS, identified as the unique superposition effects of two motion components at high frequency in the spindle vibration. In addition, the experimental result reveals that the relative distance between the rotational axis of the ABS and the tool tip varies with respect to the different spindle speeds, significantly degrading the machining accuracy.