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Procedia CIRP 58 (2017) 457 – 462

16th CIRP Conference on Modelling of Machining Operations

Optimization of high speed machine tool spindle to minimize thermal
distortion
Srinivas N. Grama * , Ashvarya Mathur, Ramesh Aralaguppi, Subramanian T.
Dr. Kalam center for innovation, Bharat Fritz Werner R&D, Off Tumkur Road, Bengaluru, 560022, India

∗ Corresponding author. Tel.: +91-80-3982-1408; Fax: +91-80-3982-1100; E-mail address: srinivas.gn@bfw.co.in

Abstract

Thermal errors contribute significantly to the dimensional error on machined components. Various machine design and operating factors are
responsible for the thermal error. In the present work, experiments are performed to understand the effect of spindle rotational speed and the
chiller unit setting on the temperature distribution in the spindle and consequently the thermal distortion of the Tool Center Point (TCP). A
metrology fixture is fabricated and calibrated to measure TCP displacements as a precursor to experimentation. In addition, multiple temperature
sensors are affixed at critical points within the spindle. It is seen that the temperature distribution across the outer race of front bearings is non-
uniform (> 2.5◦ C) which in turn indicates that the heat extraction is not uniform across the spindle. Concurrently, significant tilt (yaw and pitch
angles of the order of 50μ radian) is visible at speeds greater than 5000 rpm. In the second part of the paper, a thermal compensation model is
developed in a linear regression framework. To improve robustness of the model and reduce redundancy, only five out of eighteen temperature
sensors (two near front bearing, one each near rear bearing and motor coil and an ambient temperature) are chosen through Principal Component
Analysis (PCA) and k-means clustering. The predictions of the model agrees well with the measurements taken from a different set of experiments.

©c 2017
2017TheThe Authors.
Authors. Published
Published by Elsevier
by Elsevier B.V.is an open access article under the CC BY-NC-ND license
B.V. This
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the scientific committee of The 16th CIRP Conference on Modelling of Machining Operations.
Peer-review under responsibility of the scientific committee of The 16th CIRP Conference on Modelling of Machining Operations
Keywords: Motorized spindle, thermal modeling and compensation, machining center, thermal distortion, optimization

1. Introduction machining conditions while the variation in ambient temper-

Accuracy and precision of machined product along with
speed of machining are among the important considerations for
a machine tool manufacturer during the design of a general pur-
pose machining center. Although various proving tests are un-
dertaken in the form of leveling test, straightness calibration of
axes using laser interferometer, full power tests, etc. during the
assembly of a machining center, often significant variability is
found in the geometrical accuracy and precision of machined
end-products. The reason for such deviation from the ideal sit-
uation is the combination of following major error sources: ge-
ometric and kinematic error; cutting force induced error; tool-
wear related error and thermal error. Among these errors, it is
well known that about 40 to 70% is due to thermal issues [1].
For instance, geometrical accuracies of products machined in
a typical 12-hour shift vary widely (whether the machine was
warmed up or not, the change in the ambient temperature) due
to the inherent transient behavior of the machine tool till stabi-
lization is attained.
Thermo-elastic behavior of machine tool is dependent on a
variety of internal and external factors. The major internal fac-
tors include the design and assembly of the machine tool and
ature and existing temperature gradient in the machine shop
are some of the external factors. Various approaches includ-
ing analytical and/or numerical modeling (finite-element and
finite-difference approaches) in conjunction with experimen-
tation have been followed to describe the thermo-mechanical
behavior of the machine tool [2]. However accurate thermo-
mechanical modeling of a complete machining center under
various operating conditions is quite difficult and complicated
[3]. One of the vital machine tool component which is also a
major heat source especially in the case of high speed machin-
ing is a motorized spindle. It is therefore important to first map
the thermo-mechanical characteristics of motorized spindle.
Motorized spindle has two main heat sources: the motor and
the spindle supporting bearings. Heat generation in the motor
is because of the magnetic and electrical losses during the con-
version of electrical power to mechanical work while it is due
to friction for the case of bearings. Therefore in contrast to the
belt-driven or gear-driven spindle, the mode of heat generation
and dissipation should be taken into account during the design
of motorized spindle. This internal heat generation causes spin-
dle distortion in the form of TCP displacements which in turn
results in the degradation of machine tool performance. In or-
der to minimize this effect, machine tool manufacturers employ

2212-8271 © 2017 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the scientific committee of The 16th CIRP Conference on Modelling of Machining Operations
doi:10.1016/j.procir.2017.03.253
458 Srinivas N. Grama et al. / Procedia CIRP 58 (2017) 457 – 462

forced convection-type heat transfer with the coolant being ei-
ther air, water or oil.
To further minimize TCP displacements in high precision
machining centers, two approaches are commonly employed.
The first one is to control the heat flow or optimize the mechan-
ical design to reduce the sensitivity to heat flow either through
the use of low Coefficient of Expansion (CoE) materials or the
use of a novel cooling strategy which directly minimizes TCP
displacement itself. The second approach is to allow for spindle
distortion which is compensated electronically real-time. In the
former case, recent research [4] has shown that differentiated
recirculation systems for bearings and motor provide a better
dissipation strategy than the traditional cooling system. In ad-
dition, further improvement is seen when heat dissipation rate
is matched with the heat generation rate through the control of
the coolant entry temperature [5].
Nomenclature
T i Temperature of ith sensor in ◦ C (i = 1 to 18).
ΔT i Temperature change of ith sensor with respect to its
initial temperature in ◦ C.
ui Spindle displacement at ith location in μm (i = 0◦ ,
90◦ , 180◦ , 270◦ position).
δ Thermal expansion of spindle in μm.
N Spindle speed in rpm.
A Augmented temperature matrix with n temperature
sensors in columns and m time steps in rows.
S i Singular value of A corresponding to ith principal
component.
to group and select the temperature sensors for compensation
model development using PCA and k-means clustering. The
predictive capability of the developed model is then checked by
performing an experiment very different from the ones used to
build the model. Finally, a few concluding remarks are offered
in Section 4.
2. Material and Methods
The experimental set-up includes a stand-alone motorized
spindle which is mounted onto the milling head which in turn
is rigidly fixed to the test bed. The bearings in the spindle are
arranged in a double ◦-configuration and provision is made to
cool the bearings and stator portion of the motor region (Fig. 1)
through a recirculation-type chiller unit. Eighteen Pt100 Resis-
tance Temperature Detector (RTD) sensors are affixed at several
critical points in the spindle: four each in outer race of front
bearings, five in outer race of rear bearings, one each for motor
coil, ambient and housing temperature and finally one each at
coolant entry and exit points. A custom-built software is used
to synchronize the data from FANUC CNC controller (such as
spindle speed and motor coil temperature) along with the tem-
peratures from other RTD’s, flow rate and chiller on/off infor-
mation. Experiments are performed under no-load condition
and the resulting thermal displacements are manually measured
using high precision Millimess dial gages, which are rigidly
clamped in a specially fabricated fixture, whose details are pro-
vided in subsection 2.1.

Electronic thermal compensation through origin shifting or

feedback interception method is the most popular way of reduc-
ing thermal errors. Extensive research is conducted to arrive
at ’so-called’ robust optimal model which relates the TCP dis-
placements to various internal and external parameters such as
temperatures, strains, spindle speed, etc. Various kinds of mod-
els using either least squares, regression analysis, transfer func-
tion, neural network, support vector machine or hybrid tech-
niques have been developed and their detailed review is pro-
vided in [6]. In order to reduce the redundant data input during
model fitting, approaches including correlation grouping, group
searching have been employed and optimal sensor locations
were chosen [7]. In addition to the models which use instan-
taneous values of internal and external parameters to estimate
TCP displacements, some models employ thermo-mechanical
history data as well in order to account for the thermal time
constant of spindle unit and they show a better predictive capa- Fig. 1: A schematic of the motorized spindle with eighteen temperature sensors
bility [8]. and a representative coolant channel.
The present work is aimed at understanding the thermo-
mechanical behavior of stand-alone motorized spindle in an 2.1. Fixture development
experimental-modeling framework. The first part of the paper
is focused on experimentation wherein the effect of various op- A steel fixture (Fig. 2) is designed to measure spindle
erating parameters on the temperature distribution in the spin- distortion at four designated points (Fig. 2; points ui , i =
dle and resulting TCP displacements are studied. Specifically, 0◦ , 90◦ , 180◦ , 270◦ ) on the rotating disk. This precision ground
Section 2 describes the experimental setup, the design and vali- disk (d = 210 mm in diameter1 ) forms an extension of spin-
dation of displacement measurement fixture, the effect of spin-
dle rotational speed and spindle orientation on TCP displace-
ments. The second part is focused on the thermal compensation 1 Larger disk diameter is chosen to magnify the measurements and reduce

methodology adopted wherein Section 3 introduces a novel way uncertainty.

 Srinivas N. Grama et al. / Procedia CIRP 58 (2017) 457 – 462
dle shaft as it is rigidly clamped onto the spindle. The spindle
distortion parameters, i.e., the axial growth, δ = (u0◦ + u90◦ +
u180◦ +u270◦ )/4, the pitch angle γ x = tan−1 ((u90◦ − u270◦ )/d) and
the yaw angle γy = tan−1 ((u0◦ − u180◦ )/d) are later extrapolated
from the four measurements. The measurement procedure is as
follows: first the spindle is stopped intermittently from rotation
and oriented at a pre-designated position through ’M19’ com-
mand; then a slip gage is used to measure the gap and finally the
distortion is measured after accounting for the slip gage thick-
ness. This fixture is designed to be different from the commonly
used 5-point measurement setup (ISO 230-3 standard [9]) as it
overcomes several disadvantages: the use of a precision man-
drel is avoided and allows high speed rotation in addition to
being a low-cost set-up. Due to high resolution requirement of
measurements, the fixture alone is calibrated against a standard
granite block and the environmental temperature variation error
(ETVE) is found to be systematic across the four points (≈ 4
μm when the ambient temperature change is 6◦ C), thus pro-
viding confidence in the experimental measurements. Further,
the validity of measurements are reinforced through repetition
of experiments and they reveal a similar trend; details of which
are provided in further sub-sections.
Fig. 2: A steel fixture is used to calculate spindle distortion from dial gauge
measurements at four designated points (ui , i = 0◦ , 90◦ , 180◦ , 270◦ ).
2.2. Effect of chiller setting
The heat generated in a motorized spindle is extracted us-
ing a recirculation-type oil coolant system (chiller unit). Ambi-
ent temperature tracing strategy is employed for triggering the
chiller unit. This strategy involves manual setting of chiller dif-
ferential temperature (CDT), an integral number from +10◦ C
to -10◦ C. For instance, the compressor in the chiller unit is trig-
gered when the coolant reservoir temperature reaches ’CDT +
1◦ C’ with respect to ambient temperature, while it is switched
off when the reservoir is cooled to ’CDT - 2◦ C’. Although this
cooling system allows for the variation in trigger frequency of
compressor depending upon the heat generation rate, the dissi-
pation rate will however not match the heat generation rate [5]
causing the spindle to distort. The effect of ambient temperature
and CDT setting alone (internal heat from motor and bearings
are isolated by maintaining the spindle in stationary condition)
is studied by choosing two extreme CDT’s.
The CDT of +10◦ C reduces the triggering frequency of the
chiller unit by a great extent (time period ≈ 180 minutes) as
459
the only heat source is the friction due to pumping action and
in cooling path. The temperature of all RTD’s in addition to
the spindle disk distortion are monitored and is plotted in polar
axis (Fig. 3) as it showcases the tilt error tacitly. The polar plot
illustrates the temperature and distortion of different sensors at
their respective position w.r.t. the spindle axis. It is seen that
front bearing temperatures are uniform (≈ 38◦ C) across a sec-
tion while spindle disk distortion is non-uniform (u90◦ >> u270◦ ,
u0◦ ≈ u180◦ ; refer Fig. 2). On the other hand, when CDT is -
10, the chiller trigger frequency is very high (time period ≈ 2.2
minutes) as the heat source is the ambient temperature; the front
bearing temperatures are lower (≈ 18◦ C) while spindle disk
contracts (u90◦ << u270◦ , u0◦ ≈ u180◦ ) relative to the reference
position. As expected, axial growth (δ = 23 μm) is observed for
a CDT of +10◦ C while significant contraction (δ = -16 μm) re-
sults for CDT of -10◦ C. On the other hand, it is puzzling to find
significant tilt error (of the order of 50 μ radian) at these CDT’s
even when the spindle is stationary; work is underway to throw
light on this aspect and will be reported elsewhere. However,
for all practical applications, a CDT of -2◦ C is employed and
the same is followed in the further experiments with spindle
rotation as described in Section 2.3.
2.3. Effect of spindle speed
Speed of the spindle plays an important role in the thermal
behavior of the spindle as it dictates the internal heat generation.
Experiments are carried out at the following spindle speeds:
2000, 5000 and 8000 rpm. The temperatures are logged once
every ten seconds while the spindle distortion is measured in-
termittently (initially at a higher rate to account for the rapid
change in TCP displacements). The spindle is rotated till sta-
bilization is reached [9] after which rotation is stopped until
the spindle cools to ambient temperature. The spindle distor-
tion parameters calculated when the spindle is stationary, i.e.
approximately during 150 and 300 minutes for 5000 and 8000
rpm experiments (Fig. 4), show a decreasing trend with higher
slope just after the spindle is made to stop while it plateaus to-
wards the end of 300 minutes, i.e. when the spindle cools down
to ambient temperature. It is interesting to note that δ has not
gone back to zero reading mainly because of the increase in am-
bient temperature from the start of the experiment in addition
to the systematic error of the measurement setup. The spindle
growth, δ, calculated for all three speeds (Fig. 4) indicates its
dependence on the spindle speed and also partly on the change
in ambient temperature. In addition, the evolution of critical
parameters during 8000 rpm experiment is also illustrated in
Fig. 5, wherein the following important points are observed.
A non-uniform temperature distribution in front bearings with
a positive bias towards the third quadrant (T 3 , T 6 and T 7 are
higher compared to rest). Work is underway to reduce this bias
through the optimization of coolant circuit and will be reported
elsewhere. Further, the chiller triggering frequency is also re-
flected in T 1 , T 5 and T 8 temperatures in the form of jaggedness
in its evolution when compared to other sensors. Motor coil
temperature is higher than other RTD’s even when the spindle
is not rotating (during 150 and 300 minutes) due to magnetic
losses in the powered on condition. The ambient temperature
change is about 5◦ C, while housing is influenced by both the
ambient and front bearing temperatures. The coolant temper-
ature at the spindle outlet is higher than at inlet and the reser-
460 Srinivas N. Grama et al. / Procedia CIRP 58 (2017) 457 – 462
(a)
Fig. 3: The temperatures of front bearings FB1 and FB2 are almost uniform across a section: (a) when CDT is set at +10◦ C, the FB1 and FB2 temperatures are
around 38◦ C and distortion, u is relatively high at 90◦ position; (b) when CDT is -10◦ C, the temperatures are around 20◦ C while u is relatively low at 90◦ position.
voir temperature fluctuation is matching with the chiller trig-
gering frequency. In addition, chiller triggering frequency is
much lower during 150 to 300 minutes, i.e., when spindle is
stationary. Similar observations are also noted for other spindle
speeds and are not plotted here for the sake of brevity. Figure
6 illustrates the temperature variation across front bearing sec-
tions in conjunction with the spindle displacements. The δ after
stabilization is 32 μm with a pitch angle error of 38 μ radian
(u90◦ > u270◦ ; u0◦ ≈ u180◦ ).
Fig. 4: The spindle growth, δ depends on the rotational speed as well as the
ambient temperature.
3. Compensation modeling
Electronic compensation provides an economic and effective
way to minimize thermal errors. A compensation model pro-
vides an implicit/explicit relation between the internal/external
parameters of the machine tool and the TCP displacement. As
described in Section 2, temperature sensors were affixed in the
spindle at 18 positions, which were decided on the basis of
engineering judgment. However the inclusion of all tempera-
ture sensors in the model will increase its redundancy due to
the apparent high correlation between temperatures. In order
to reduce model redundancy, selection of optimal temperature
points is critical and the procedure adopted in this work is de-
tailed in the next sub-section.
(b)
3.1. Grouping and selection of temperature sensors
Various approaches including engineering judgment, cor-
relation analysis, stepwise regression, sensitivity analysis and
fuzzy clustering [7,10] are used to group the temperature sen-
sors and select optimum ones for compensation modeling. In
the present work, Principal Component Analysis (PCA), a
multi-variate statistical technique, commonly used to reduce
the dimensionality and de-noise data, is proposed to cluster the
temperature sensors. Uncentred PCA [11,12] is used as we are
dealing with ’ratio-scale’ type variables. The first step is to as-
semble the temperature data obtained from the experiments de-
scribed in Section 2.3 and build an augmented matrix, A, such
that the columns represent different sensors while the rows indi-
cate temporal information of temperatures. Uncentred PCA is
performed on A through Singular Value Decomposition (SVD)
route:
A(m×n) = l(m×m) S(m×n) rT(n×n) , (1)
where l = [el1 el2 el3 ... elm ] contains left eigenvectors (i.e.
those of AAT ) in the columns and r = [er1 er2 er3 ... ern ]
contains right eigenvectors (those of AT A) in the columns. The
matrix S contains r = rank(A) non-zero singular values along
the diagonal while all other elements are zero. If significant cor-
relation exist within n temperature sensors, then several singu-
lar values are much smaller than others. In fact, if only p << r
singular values are seen to be dominant, one may reconstruct
the original matrix A entirely in terms of the first p right or left
eigenvectors, and the reconstruction error is equal to ratio of
the sum of the discarded singular values to the sum of all sin-
gular values [13]. The Log Singular Value (LSV) spectrum of
A (Fig. 7) shows a gradual decrease in singular values and only
five singular values (and vectors) contain more than 99% of the
information. This fact is used to group the sixteen temperature
sensors (the inlet and outlet coolant sensors are excluded) into
5 clusters through the k-means clustering algorithm [14]. The
clustered temperature sets shown in Table 1 match the engineer-
ing judgment: the first and second clusters consists of sensors
in front bearings with typically lower temperatures belonging to
the former while T 3 , T 6 and T 7 sensors, with relatively higher
temperatures, forming the latter; the third cluster is formed by
all the rear bearing temperatures while the fourth is made up
 Srinivas N. Grama et al. / Procedia CIRP 58 (2017) 457 – 462 461

(a) (b)

(c) (d)

Fig. 5: The parameter evolution at various points of the spindle unit when the spindle is rotated at 8000 rpm: (a) front bearing FB1 RTD’s indicate temperature
difference >2.5◦ C between sensors T 3 and T 1 , (b) front bearing FB2 RTD’s also indicate a similar variation in temperature across its outer race, (c) The ambient
temperature change is around 5◦ C while housing is influenced by both ambient and front bearing temperatures. Motor coil temperature is higher than other RTD’s
even when the spindle is not rotating (during 150 and 300 minutes) due to magnetic and other losses in the powered on condition and (d) the coolant exit temperature
is higher compared to the entry temperature and the chiller triggering frequency is much lower during 150 to 300 minutes, i.e., when spindle is stationary.

Fig. 6: Temperatures in the front bearings FB1 and FB2 are of a higher magni-
tude in the region between 150◦ and 290◦ while higher spindle displacement is
Fig. 7: The LSV spectrum of A shows a gradual decrease in singular values and
seen at 90◦ and 180◦ region.
99% of the data is captured in the first 5 principal components.

of ambient and housing sensors and finally the motor coil sen-
sor alone forms the fifth cluster. These grouping of temperature
sensors into the above five clusters are in line with our observa- Table 1: The temperature sensors are classified into 5 different clusters using
tions from Fig. 5 and Section 2.3. k-means clustering analysis.

Cluster-1 Cluster-2 Cluster-3 Cluster-4 Cluster-5

3.2. Regression modeling
T1 (FB1) T 3 (FB1) T 9 (RB1) T 12 (AMB) T 18 (COIL)
In order to evaluate the performance of combined PCA and T2 (FB1) T 6 (FB2) T 10 (RB1) T 17 (HOUS)
k-means clustering-based technique for temperature sensor se- T4 (FB1) T 7 (FB2) T 11 (RB1)
T5 (FB2) T 13 (RB2)
lection, a thermal error prediction model is developed based on
T8 (FB2) T 14 (RB2)
multi-linear regression (MLR) method. Diverse experiments
including 2000, 5000 and 8000 rpm spindle speed are used as
training dataset to fit the model. Due to the use of multiple ex-
462 Srinivas N. Grama et al. / Procedia CIRP 58 (2017) 457 – 462
periments during model development, care is exercised to en-
sure that no systematic error is carried into the model by adopt-
ing relative temperatures ΔT i (one sensor chosen from each
cluster, for instance, i = 1, 3, 9, 12, 18, such that only the change
in temperature w.r.t its initial temperature is used) as model pa-
rameters instead of the absolute temperature values. The model
form is chosen as follows:
 bias towards the third quadrant. Concurrently, yaw and
δ p = β0 + βi ΔT i , (2)
i served after stabilization (spindle speed of 8000 rpm).
where βi are the coefficients determined by solving an over-
determined set of linear equations using standard numerical
techniques. For the present set of experimental measurements,
β = [3.02, -1.99, 4.92, -1.03, -2.41, 0.26] and R2 value is found
out to be 0.95. The goodness of fit also reiterates the fact that
the assumption in model type as a linear one turns out to be ad-
equate. The predictive capability of the model is then checked
by performing a set of experiments different from the ones used
to build the model; details of which are provided in Section 3.3.
3.3. Predictive capability of model
The linear regression type thermal compensation model de-
veloped in Section 3.2 is put to a challenging test by performing
a variable spindle speed test. The spindle speeds are varied from
0 rpm to 8000 rpm and for different intervals of time (Fig. 8). It
is noted that a higher spindle speed has a dominating effect on
the spindle growth δ. For instance, at around 200 minutes when
spindle is rotated at 8000 rpm, the slope of δ is quite high and it
becomes much lower at lower spindle speeds. The δ p obtained
from the developed model fits very well with the measured δ
(Fig. 8) and R2 value is 0.94. This confirms that the developed
compensation model can be used to predict the axial thermal
displacement of the stand-alone motorized spindle.
Fig. 8: The predictions of the developed model agrees quite well with the ex-
perimental measurements for a variable spindle speed test.
4. Conclusion
The following are the major conclusions from the com-
bined experimental-modeling work to understand the thermo-
mechanical behavior of stand-alone motorized spindle:
• Spindle distortion including the tilt and axial thermal error
is calculated using dial gages mounted on a custom-built
calibrated fixture.
• The cooling strategy employed plays a very important role
on TCP displacements. Even when the spindle is station-
ary, significant pitch angles of 57 μ radian and 38 μ radian
are observed at CDT setting of +10◦ C and -10◦ C respec-
tively. Also, axial displacement of 23 μm and -16 μm is
observed at +10◦ C and -10◦ C CDT setting respectively.
• During spindle rotation, non-uniform temperatures are ob-
served in the outer race of front bearings with a positive
pitch angles of 5 and 38 micro radian respectively are ob-
• A compensation model is developed in a linear regression
framework using five temperature sensors chosen through
combined PCA and fuzzy clustering analysis.
• The developed model is able to predict the axial displace-
ment of spindle for a different set of experiment quite well
with an R2 value of 0.94.
Acknowledgements
SNG and AM thank the top management of Bharat Fritz
Werner for providing financial support. They also thank Math-
works for providing an evaluation version of Matlab software.
Finally, the services extended by Mr. Puneeth M., laboratory
technician, during experimentation is duly acknowledged.
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