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Thermal Science and Engineering Progress

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Developing a thermoelectric cooling module for control temperature and

thermal displacement of small built-in spindle
Thi-Thao Ngo a, Chi-Chang Wang b, Yen-Tung Chen b, Van-The Than a, *
a
Faculty of Mechanical Engineering, Hung Yen University of Technology and Education, Khoai Chau, Hung Yen, Viet Nam
b
Department of Mechanical and Computer-Aided Engineering, Feng Chia University, No. 100 Wenhwa Rd., Seatwen, Taichung 40724, Taiwan ROC

A R T I C L E I N F O A B S T R A C T

Keywords: In a small built-in spindle, cooling by air and water is usually employed to maintain stability of temperature
Small Built-in Spindle which helps to reduce thermal errors and extended spindle life. This paper presents a Thermoelectric Cooling
Thermoelectric Cooling Module Module (TCM) to potentially replace conventional air cooling system for controlling temperature as well as
Fast Heating
thermal displacement on the small built-in spindle. A Proportional-Plus-Integral-Plus-Derivative Control Action
Temperature control
Thermal displacement
(PID) is integrated in TCM to continuously control temperature on the spindle. Based on considered effects of
each PID adjustment coefficient on temperature, an appropriate set of parameters for temperature control is
determined. Results show that time for achieving steady-state temperature has reduced 47% by using TCM
cooling system. Thermal displacement using TCM system is also decreased 77μm compared to utilizing the air
cooling system. Besides, energy consumption of TCM system only equals 1/16 of that of the air cooling system. In
addition, relationship of thermal displacement with some temperatures is carried out based on the least square
function. Hence, it can say that TCM is more effective than the traditional air cooling system in the small built-in
spindle.

1. Introduction
Nowadays, small built-in spindles (SBS), are often rotated under
ultra-speed for machining small to micro products. Rotation of SBS is
supported by high-speed ball bearings or aerostatic bearings. SBS is also
integrated motor its inside (sometime called small motorized spindle).
Therefore, SBS has some advantages such as faster in starting, good at
dynamic balance, no belt forces etc. Because a motor attached inside the
spindle, it will generate a large amount of heat, which causes rapidly
increasing temperature in the spindle. However, the spindle should be
maintained temperature lower critical temperature to reduce thermal
error. Therefore, SBS is usually cooled by a system such as air or water
channels. Si Yu Gao et al. [1] used an integrated multi-physics simula­
tion platform to optimal design for a high-speed aerostatic spindle.
Structure of the spindle including bearing location, water-cooling sys­
tem has been analyzed. An optimal design of the bearing and water-
cooling system was carried out based on simulation. Dynamic and
thermal behaviors were then validated by experiments. Finite element
analysis coupled CFD to simulate cooling system and structure charac­
teristics of a ultra-high speed spindle for finding an optimal design was
presented in reference [2]. In this design, a helical water cooling channel
was chosen for cooling. Shuyun Jiang and Shengye Lin [3] extended
cooling system for an ultra-high-speed motorized spindle during grind
small-deep hole. A coolant line was located in the shaft for not only
cooling but also bring grinding chips. A study on a high speed micro-
machining spindle was presented by B. Knapp [4]. In the spindle, the
water-cooling was used for controlling temperature and further helped
reducing thermal deformation. E. Creighton et al. [5] investigated a
micro-milling spindle which used air-cooling channels through its body.
Air-cooling system has advantage of not worry about leakage as water-
cooling system. For disadvantage, with cooling by air, heat is dissipated
based on pressured air that is provided by a compressor; air flow through
runner inside spindle will carry out the heat on rotor and stator surfaces
as well as bearings by force convection phenomenon; while friction
between continuous high pressure air with spindle structure, for
example, motor surfaces, bearings etc. is causes to lead power loss.
Through above analysis, it is shown that water- and air-cooling systems
are common applied in the SBS. The cooling system is a main part of
energy consumption in machine tool [6]. In fact, innovative quality SBS
is not only focus on precision but also needed considering energy loss.
However, mentioned above researches have not been given an attention
for total energy consumption, especially energy supply for cooling sys­
tem. In present study, a cooling system, which saves energy, will be

* Corresponding author.
E-mail address: thanthe.ck@gmail.com (V.-T. Than).

https://doi.org/10.1016/j.tsep.2021.100958
Received 6 November 2020; Received in revised form 18 April 2021; Accepted 4 May 2021
Available online 11 May 2021
2451-9049/© 2021 Elsevier Ltd. All rights reserved.
T.-T. Ngo et al. Thermal Science and Engineering Progress 25 (2021) 100958

caused by fluid heat boundary layer thickness in the cooling channel

Nomenclature increases with length due to high velocity of gas and special runner
design. In addition, a gas channel reserved inside the spindle will reduce
T Temperature [◦ C] stiffness of the spindle. However, applying TMC for cooling SBS can
t Time [s] discard this problem.
In recent years, thermoelectric cooling technique is one of high ef­
Greek symbols ficiency and low energy consumption methods based on using Inte­
δ Thermal displacement[μm] grated Circuit (IC) equipment cooling. Thermoelectric Cooling Module
Subscripts (TCM) is a technique for dissipating heat. Yang et al. [7] analyzed a
FB Front Bearing cooling mode, material and physical parameters of TCM. They pointed
RB Rear bearing out that overall coefficient of performance value can be increased by
Gss Gap of spindle seat enhancing heat dissipation efficiency of TCM heat delivery surface and
Cis Cast iron seat further making higher cooling efficiency. Fredes et al. [8] applied TCM
Set Setting temperature and Proportional Integral Derivative to control temperature junction of
Surr Ambient temperature UV-C LED. Controlling temperature junction can make the UV-C LED
having longer service life, reliability, efficiency and wavelength accu­
racy. Åström et al. [9] studied different adaptive techniques, elementary
process models and PID control design, and adjusted method to obtain a
better PID parameters to help it more stabilize and reducing errors. Ang
et al. [10] designed and analyzed the PID control system and they
elaborated difficulties in academic and practical applications. Above
analysis indicate that TCM system has not been applied for cooling in
SBS. In this study, a Thermoelectric Cooling Module (TCM) is developed
to maintain temperature on SBS. The TCM has features of quick response
on temperature, low cost as well as saving energy.
Thermal error always accompanies in the spindle and it significantly
take into account total thermal errors of machine tool. A lot of re­
searchers have been studied on thermal error in the spindle. Thermal
error caused by thermal expansion that is resulting from increased
temperature on the spindle due to heat generation including motor and
bearing. Some authors tried to reduce heat source and thermal expan­
sion through utilizing some appropriate material such as ceramic
bearing, carbon fiber etc. [11,12]. Another researchers have applied
optimal structure design, cooling system to acquire an uniform tem­
perature distribution in the spindle that further helps controlling ther­
mal error [13,14]. However, these two methods are often difficult
during manufacturing process and can reduce a part of thermal error,
which has not been achieved demanded value. Therefore, a flexible and
more accurate method for spindle thermal error problem is compensa­
tion. Predicting and compensating for thermal errors of the spindle is an
important task to improve machine tool precision and manufacturing
quality. Function of thermal effects on the spindle elongation may
import to CNC controller for adjusting tool position and further reducing
machining errors. Many researches have been studied and found method
to predict and compensate thermal error on the spindle as well as ma­
chine tools. Li et al. [15] gave a preview about estimation and
compensation of thermal deformation technique to make cutting accu­
racy more stable and effective. Some techniques such as least square
error [16], linear regression [17], grey neural network model [18], etc.,
were utilized to build relationship of temperature or spindle speed and
thermal displacement based on significant temperature points. Recently,
Shen Hongyao et al. [19] proposed a method to make a thermal
compensation according to double-LSP model. Their results shown that
predicted thermal deformation was acquired up to 84.84%. Yang et al.
[20] predicted thermal error of high speed spindle based on DOE-FEM.
Estimated results by DOE-FEM was then compared to that acquired by
the regression method. Zhengchun Du [21] used theoretical analysis to
Fig. 1. Heat transfer of internal cooling runner. optimize temperature sensor location. A linear function of temperature
and deformation was given. Comparison of simulated and experimental
results indicated that thermal error was decreased by 73%. The thermal
investigated and developed for SBS. Beside this system also can elimi­
error of three-dimensional space detection of six vector eight-test was
nate heat loss due to high pressure-air friction.
presented by Changyong Zhao et al. [22] for spindle in horizontal CNC
An exploration simulation of gas velocity and temperature distribu­
machine tool with large torque. Effectiveness of the authors’ method
tion in SBS using pressured air cooing system is performed and results
was validated through machining a S-specimen which recommended by
are shown in Fig. 1. It is exposed that conventional air cooling with long
ISO 10791–1. A deep learning was utilized for predicting spindle ther­
and narrow runner is poor endothermic. This phenomenon can be
mal error based on temperature recorded by infrared camera [23]. A

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T.-T. Ngo et al. Thermal Science and Engineering Progress 25 (2021) 100958

(a) Conventional air cooling system

(b) Cooling process

Fig. 2. Schematic conventional built-in spindle air cooling.

Fig. 4. Temperature recorded by thermal imager under 60,000 rpm.

Fig. 3. Structure of built-in spindle and TCM setup.

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T.-T. Ngo et al. Thermal Science and Engineering Progress 25 (2021) 100958

Fig. 5. Spindle with developing TCM system.

Table 1 experimental temperature. However, thermal error has not considered

Features of TCM, fan and cooling fin. for studying on SBS until now.
TCM MaxCurrent MaxVoltage Max Cooling force E. Creighton et al. [5] also studied on thermal deformation of a
(FROST-74) 6.3A 16.7 V 65 W micro-high speed milling. They applied finite element analysis to predict
temperature and thermal deformation of the micro-high speed milling.
Fan RPM dB Air volume (CFM)
(FUB0412VHN) 9500±10% 45 15.79 An experiment was also conducted to measure temperature and thermal
Fin Material Number of fins Size of single fin deformation under varying speeds. Spindle speed was added in an
Long × High × Thick exponential in nature for modeling thermal deformation. Than et al.
[mm] [25] expressed a formula of axial thermal displacement of an small
Aluminum 84 17 × 25 × 1 motorized spindle based on one-dimensional model. Axial thermal
alloy
displacement was calculated using temperature measured on the spin­
dle. Spindle speed was also composed in the formula. A function of axial
combination of the variational mode decomposition (VMD), grey wolf thermal displacement was then demonstrated for varying speeds.
(GW) and long short term memory (LSTM) for predicting thermal error However, the temperature in their study has not been controlled during
of spindle system was demonstrated in reference [24]. Compensation changed spindle speed. Through literature review, it is shown that non-
performance of the VMD-GW-LSTM network model was far better than researcher has spent an attention on functional thermal deformation of
that of VMD-LSTM network and RNN models. Above analysis reveal that SBS based on only measured temperature. In present research, the least
these studies have proposed methods to model and compensate thermal square function is applied to model the thermal displacement of SBS
error for spindle as well as machine tool based on simulated and utilized experimental temperature which is maintained as constant by
TCM under varying speeds.

Fig. 6. Experimental structure.

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T.-T. Ngo et al. Thermal Science and Engineering Progress 25 (2021) 100958

Fig. 7. Circuit for temperature control.

2. Experimental construction
A conventional air cooling equipment and cooling process are shown
in Fig. 2. Surrounding air is compressed, dried and then flowed pipe into
gas tank. After that, gas flow rate was adjusted through a pressure regu­
lating valve pipeline to runner inside spindle for carrying internal heat
(motor and bearing heats) away and further resulting on temperature in
SBS. From Fig. 3, it can be seen that SBS is supported by two ball bearing
located at front and rear of the spindle (refer to Fig. 3(a)). Cooling runner
with rectangle cross-section that contacted with stator and spindle hous­
ing is described in Fig. 3(b). Length and diameter of the spindle housing
are 192 mm and 50 mm, respectively. In addition, maximum spindle
speed can be reached 60,000 rpm with power rate of 350 W.
In order to determine TCM mounting position, the spindle is run
under maximum speed (60,000 rpm) and temperature distribution on
the housing is recorded by thermal image. From Fig. 4, it is observed that
high temperature is mainly distributed in regions of the front, rear
bearings and motor coil. Therefore, the TCM is assigned to mount be­
tween front and rear bearings. Fig. 5 presents the spindle with TCM
system. A chip heat delivery surface is provided with fins and fan to
enhance heat transfer efficiency. Characteristics of TCM, fan and cooling
fin are presented in Table 1. T-type thermocouple is utilized to measure
temperature at five points including front (TFB), rear bearings (TRB),
spindle seat gap (TGss), cast iron seat (TCis) and ambient temperatures
(TSurr); they will provide main information for controlling whole tem­
perature and further use to predict thermal displacement. Besides, an
eddy current displacement meter is used to measure the thermal
displacement at tip of spindle shaft. A completely experimental diagram
of cooling system for SBS is given in Fig. 6. A power supply provides
voltage for motor speed regulator. Temperature of all channels and

Fig. 8. Diagram of whole TCM control system.

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T.-T. Ngo et al. Thermal Science and Engineering Progress 25 (2021) 100958

adjust the voltage and resulting on control the temperature of the

spindle. These processes are drawn out in Fig. 7. Designed temperature
equals 38 ◦ C which is selected closed to ambient temperature for saving
energy during spindle cooling. The control system will be activated
when different between front bearing and the designed temperatures
higher than 0.8 ◦ C. In order to avoid the TCM switching heating and
cooling frequently in a short period time which effects on heat transfer
efficient and lifetime, the state of cooling is only switched if e(t) > ΔT =
0.5 ◦ C during the heating process, and vice versa. From above analysis, a
detailed algorithm for coding is illustrated in Fig. 8.

3. Small built-in spindle thermal error model

A function of the spindle temperature changes and thermal

(a) Effects of K p on temperature oscillation
displacement is obtained by linear regression in this paper; the least
square function is used for regression analysis of mathematical modeling
to obtain the relationship between one or multiple independent tem­
peratures and dependent thermal deformation. For multi-point linear fit
prediction model can be expressed as follows
δ = b0 + b1 T1 + b2 T2 + b3 T3 + .... + bi Ti , with i = 1, 2, 3... (1)
where δ and Ti represent the thermal displacement and temperature
at the ith measured point at any time, respectively. If there are m dis­
placements corresponding temperature at different time, Equation (1)
will be given in matrix form as
⎡ ⎤ ⎡ ⎤⎡ ⎤
δ0 1 T1 T2 … Ti b0
⎢ δ1 ⎥ ⎢ 1 T1 T2 … Ti ⎥⎢ b1 ⎥
⎢ ⎥ ⎢ ⎥⎢ ⎥
⎢ δ2 ⎥ = ⎢ 1 T1 T2 … Ti ⎥⎢ b2 ⎥
⎢ ⎥ ⎢ ⎥⎢ ⎥ (2)
⎣ ⋮ ⎦ ⎣ ⋮ ⋮ ⋮ ⋮ ⋮ ⎦⎣ ⋮ ⎦
(b) Effects of K d on temperature oscillation
δm 1 T1 T2 … Ti bm

or expressed in vector form as below:

δ = TB (3)
In order to obtain coefficients bi of B vector in the thermal
compensation model, the most popular way is to use the least squares
method to acquire the optimal solution of array B

(4)
′ ′
B = (T T)− 1 T δ
After obtaining B coefficient matrix, from measured temperature at
time, thermal deformation will be easily determined by Equation (4).

4. Results and discussions

4.1. Effects of PID coefficients on temperature

(c) Temperature results with using Ziegler and Nichols Rule

Fig. 9. Effects of control parameter adjustment on temperatures.

In this section, effect of adjustment parameters of PID on tempera­
ture control process is presented. Spindle speed is maintained at
maximum of 60,000 rpm and demand temperature of 380 C. It is noted
Table 2 that the demand temperature is chosen with regarding ambient tem­
Effects of Kp and Kd on maximum error of temperature. perature in practical application. A law proposed by Ziegler and Nichols
Kp Kd [26] is combined with Trial and Error method to adjust appropriate
Value Max error[℃] Value Max error[℃] control parameters for this system. Firstly, both of Ki and Kd are set
equally zero and Kp is changed to consider its effects on steady-state
0.5 0.805 0.01 0.573
2 0.599 0.6 0.211
temperature. Temperature results for different value of Kp are dis­
20 0.392 5 1.009 played in Fig. 9(a). It can be seen that there is an oscillation of tem­
80 0.406 10 0.806 perature with all value of Kp . From data listed in Table 2, it is revealed
that maximum temperature errors of Kp = 20 and Kp = 80 are less than
that of Kp = 2. However, with Kp = 2, period of temperature oscillation
thermal displacement are collected by ADVANTECH USB-4718 and sent
is the most stability and oscillating period Pu is about 144. Therefore,
to a computer for processing data. In addition, another ADVANTECH
value of Ki and Kd can be easily calculated and they equal 0.033 and
USB-4704 is used for analog and digital control the motor speed regu­
10.80, respectively.
lator as well as relay; all data collected via this two hardware are pro­
Secondly, effect of Kd is considered through adjusting it by 5 levels
cessed by PID which is programed in computer based on C#. After that,
with keeping Kp = 2 and Ki = 0.033. Fig. 9 (b) presents temperature
information of the TCM power level and whether cold/hot side switch is
assigned and send back to power supply via ADVANTECH USB-4704 to results under different value of Kd . It indicates that curvilinear trend of

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T.-T. Ngo et al. Thermal Science and Engineering Progress 25 (2021) 100958

Fig. 10. Comparison of front bearing temperatures.

Table 3
Comparison of power consumption. Table 4
Characteristics of conventional air cooling and TCM.
Air cooling TCM cooling
system Air cooling TCM
Air compressor Air dryer TCM Fan
Cooling capacity Well Excellent
Operating voltage and current 176 V 171 V 12 V 12 V Equipment Volume Big Small
13.68A* 1.59A 3.9A 0.24A Cost High Low
0.198A** Reaction speed Slow Fast
Power consumption[kWh] 7.81 Heating &cooling Cooling Both
0.49 Water Hammer A little No
Temperature control No Yes
* Compressor operating current, 1 min per cycle. Power consumption High Low
** Compressor standby current, 4 min per cycle.

front bearing temperature is lower than the target temperature point. It
is revealed that the system response is likely to be ahead of time and
divergent if the differential control coefficient is too large. As a result,
the system interference resistance is worsened and difficult to be
controlled at the set value. In addition, temperature fluctuation is
reduced obviously due to reduce Kd and minimum of the temperature
fluctuation is reached under Kd = 0.6. In addition, maximum temper­
ature error of case Kd = 0.6 is also smallest compared to other cases
(refer to Table 2).
Finally, for effect of Ki , value of this coefficient is change to find out

Fig. 11. Temperature of all thermocouples with TCM cooling.

7
T.-T. Ngo et al.
Fig. 12. Results of TFB and thermal displacement under various spindle speeds.
approximate result. However, it is not possible to fully obtain stability of
temperature after adjustment. This is probably due to a complex spindle
structure that leads to high inertia in the control temperature; and a
delay phenomenon in temperature will be appeared.
Based upon considering effect of all PID coefficients, only two control
modules of PD are used for spindle temperature control system in this
study. Fig. 9(c) shows temperature results using PD for control with
several designed temperature and spindle speed. Results exposes that
the temperature oscillation TFB is much smaller than that of using PID for
all cases at stable state. Therefore, the PD control is utilized for rapid
heating and temperature control as well as for reducing thermal
displacement.
4.2. Comparison of cooling effective
To compare effective of pressured gas cooling and TCM on temper­
ature, SBS is run under maximum speed of 60,000 rpm to get temper­
atures. TCM is performed with power of 46.8 W, while two pressure
levels of gas at 1kgf/cm2 and 2kgf/cm2 are applied in the conventional
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Thermal Science and Engineering Progress 25 (2021) 100958
air cooling system. Temperatures at front bearing with using TCM and
pressure gas cooling are displayed in Fig. 10. Results indicates that if
using 1kgf/cm2 of gas pressure, the temperature at front bearing ob­
tained by pressure gas cooling is higher than that acquired by TCM about
20 C. After that, increased pressure of air into 2kgf/cm2 (twice), tem­
perature received from the pressure air cooling is decreased and less
than result get by TCM about 1 ◦ C. In addition, total power consumption
of two cooling methods is given in Table 3. For conventional air cooling,
power consumption comes from air compressor, and air dryer. With air
compressor, the power consumption is divided into two periodic
including cycles of 1-minute actuation and 4-minute standby. Total
power consumption of conventional air cooling system is 7.81kWh,
which is much larger than that of TCM (0.49 kWh). Thus, applying TCM
system, the power consumption can save about 15.9 times compared to
air cooling system. In addition, Fig. 11 presents temperatures at five
thermocouples under TCM cooling. Observably, difference of TFB and
TRB (in SBS) is less than 5 ◦ C; therefore one can be said that TCM cooling
system is able to make an equalization of temperature distribution in the
spindle which is a method for thermal error control [15].
T.-T. Ngo et al. Thermal Science and Engineering Progress 25 (2021) 100958

Fig. 13. Experimental data for linear regression fitting.

Table 5
Maximum prediction thermal displacement errors for different number and location of thermocouples
Cases Measurement points Average fitting error (μm) Prediction of average error (μm) Average error (μm)

60,000 rpm 50,000 rpm Varying speed

1 TFB , TRB , TGss , TCis , TSurr 1.8 3.60 2.79 4.37 3.59
2 TFB , TRB , TGss , TCis 1.7 3.12 2.95 4.50 3.52
3 TRB , TGss , TCis 2.0 3.27 2.37 5.86 3.83
4 TFB , TRB , TCis 3.3 3.25 3.70 4.51 3.82
5 TFB , TCis 3.3 3.19 3.46 4.47 3.71

4.3. Comparison of thermal displacement

Thermal displacement on the spindle is always a concern as it greatly

affects machining accuracy. Hence, thermal displacement is experi­
mentally carried out with two cooling method under varying speed. SBS
will be operated at maximum speed of 60,000 rpm and then the speed is
dropped by 10,000 rpm for each step until it reaches 10,000 rpm.
Fig. 12 illustrates temperature at front bearing and thermal
displacement for both cases of using gas and TCM cooling system. As
seen, temperature at front bearing reaches stable-state after about 6.5
min with using TCM while that is about 14.1 min with utilized gas
cooling. It can be explained that TCM cooling system has heating mode
which can quickly help temperature in SBS reaching stable state. Nor­
mally, the spindle as well as machine tool are necessary required a non-
productive warm-up procedures to reduce thermal error [12]. Thus,
short time for warm-up spindle will help us receiving more benefits.
Moreover, temperature TFB is still stable under TCM cooling system
Fig. 14. Experimental and predicted thermal displacement using two temper­
when reducing speed; while temperature TFB of case utilized air cooling
atures (TFB, TCis).
system decreases with decreasing spindle speed. This difference exists
due to TCM cooling system provides fast heating at initial operation of
Moreover, a comparison of characteristics of conventional air and
spindle and performs temperature control after reached demand tem­
TCM cooling systems is given in Table 4. It is pointed out that the air
perature; differentially, air cooling system only uses air flow resulting in
cooling equipment has large volume and high cost. It is because the
dissipated constant heat flux on spindle because the air pressure is not
system includes dryer and compressor as well as storage tanks. While
changed corresponding with varying speeds.
TCM system is compactness, low energy consumption, quick response
Also, Fig. 12(a) shows that maximum of δ during air cooling is about
and low price. TCM is a technical application that generates negative
120.8μm. In addition, due to the gas compressor switched periodically to
thermal resistance. DC power flows through a couple formed by series
maintain working pressure, there is periodically reflect on change of the
connection of two different semiconductor materials in the TCM. Both
spindle temperature and thermal displacement. It is also observed that
sides of TCM can be absorb heat and release heat rapidly; and the tem­
front bearing temperature exists a quite large oscillation amplitude
perature difference between cold and hot sides may larger than 70 ◦ C.
which induces on thermal deformation, especially at high speed. On the
contrary, with TCM cooling system, both of the front bearing

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T.-T. Ngo et al.
Fig. 15. Validating predicted thermal displacement.
temperature and thermal displacement have slightly oscillation under
varying spindle speed (refer to Fig. 12(b)). The observed maximum of δ
is about 43.8μm for case of using TCM. Besides, differences of thermal
displacement at a range of speed of 60,000 rpm to 10,000 rpm are about
42μm and 16μm under air and TCM cooling system, respectively. It is
found that after warm-up spindle, TCM cooling system can decrease
26μm of thermal deformation. Thus, TCM can maintain temperature and
further significantly reduces thermal displacement in SBS which will
enhance cutting accuracy.
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Thermal Science and Engineering Progress 25 (2021) 100958
4.4. Thermal displacement model
A reduction in thermal expansion has been demonstrated through the
above comparison. However, in order to improve the machining quality
when using SBS, error can be further declined by heat compensation. To
compensate for thermal displacement, model of thermal error firstly
needs to find out. Temperature data is received by operating SBS under
varying speeds (60,000 rpm to 10,00 rpm). For each speed, SBS will run
until the thermal displacement achieved a steady state before switching to
T.-T. Ngo et al.
another speed. In addition, TCM is activated to control temperature at
front bearing achieving expected temperature (38 ◦ C). Fig. 13 shows
temperature and thermal error results. Based on these data, relationship
between temperature and thermal displacement of SBS at different rota­
tion speeds can be established by linear regression.
Based on measured temperatures, curve fitting is applied to obtain
the function that describes relationship of thermal displacement and
temperature. A combination of different numbers and locations of
temperature is utilized as input data for linear regression process. These
functions are issued as
δ5M = 2.75TFB − 8.68TRB + 5.67TGss + 11.89TCis − 1.84TSurr − 29.11 (5)
δ4M = 2.51TFB − 9.14TRB + 5.72TGss + 12.28TCis − 87.25 (6)
δ = − 13.08TRB + 5.96TGss + 15.9TCis − 158.78 (7)
δ = − 3.02TFB − 1.26TRB + 7.36TCis + 11.06 (8)
δ = − 3.81TFB + 5.77TCis + 43.95 (9)
Average difference of measured and predicted thermal error for all
cases are small and they are listed in Table 5. It is shown that average
predicted thermal error of case using five and four input experimental
temperatures are lower than that of other cases. With using two tem­
peratures, the average predicted thermal error is the third smallest value
(3.71μm). Fig. 14 shows a comparison of predicted and measured ther­
mal displacements under constant speed and using only two tempera­
tures data (TFB and TCis ). This function is then applied to predict thermal
error for various speeds (refer to Fig. 15). Results demonstrate that mean
errors between measured and predicted thermal displacement are less
than 4.47 μm which is significantly decreased comparing to initial one.
From analysis results, it clarifies that the thermal displacement can be
accurately estimated based on only two experimental temperatures.
Because of using two measured temperatures (TFB and TCis ), the thermal
displacement will be instantly obtained by Equation (10) and then sent
feedback to machine tool for compensation. As this way, real time
compensation can be developed to improve precision of SBS.
4. Conclusion
A TCM system has been successfully developed to rapid heating or
cool the small built-in spindle for controlling temperature as well as
thermal displacement in this study. Results indicate that temperature of
the spindle can be rapidly reached steady-state after 6.5 min by using
TCM instead of 14.1 min with conventional gas cooling system. In addi­
tion, maintained temperature by TCM is much efficiency than that by
conventional cooling method due to saving time and low power con­
sumption. Curve fitting method is applied to carry out function of thermal
displacement and temperatures. Results show that the function based on
only two temperatures at front bearing and cast iron seat can accurately
predict thermal displacement with error lesser than 4.47 μm for both
constant and varying speeds. The predicted thermal displacement can be
fed back to the machine tool controller instantly for spindle thermal
compensation. Therefore, it helps enhance and stabilize product accuracy
during machining as well as increase efficiency of engineering industry.
Declaration of Competing Interest
The authors declare that they have no known competing financial
interests or personal relationships that could have appeared to influence
the work reported in this paper.
Acknowledgement
Thanks for the subsidy of the Outlay MOST 109-2221-E-035 -006
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Thermal Science and Engineering Progress 25 (2021) 100958
-MY2 given by Ministry of Science and Technology, Taiwan R.O.C, to
help us finish this special research successfully.
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Institution of Mechanical Engineers, Part J: Journal of Engineering Tribology 230
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