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1994 by Alexander H.

Slocum

Aesops1 Surface Self Compensated Profile Rail Linear Hydrostatic Bearing System: The HydroRail

Patents pending. Aesop, Inc. PO Box 2126, Concord, NH 03302-2126, Fax 603-224-5369

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1994 by Alexander H. Slocum

The carriage contains all the hydrostatic compensation and pockets on its unique surface shape2

This patented design was the subject of Ntahn Kanes Ph.D. thesis with Prof. Slocum at MIT.

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1994 by Alexander H. Slocum

The small protrusion on the rail center acts as the surface self compensation system:

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1994 by Alexander H. Slocum

Performance of a size 45 HydroRailTM bearing verses a high end rolling element linear guide.
The HydroRailTM Vs. a high end rolling element bearing
Size 45, @1190 psi HydroRail
TM

Size 45 Rolling Element Bearing


Ultra Precision, 0.03 Preload Lateral 110,000 6,500 4.6 3.0 Compress. 29,750 3,000 6,7 1,000 5.1 7 0.8 8 6.2 8 27 50 7 3.2 7 40 10 9.4 7 21.0 7 45 8 17 8
5,7

Bearing

Nominal gap = 0.001 in. Compress. Static Load which causes permanent damage Dynamic Load Capacity at given Life Life Static Stiffness Dynamic Stiffness at Resonance Q (Damping Factor) Maximum Speed Maximum Acceleration Static Friction Motion Resolution Friction @ 0.5 m/s Friction Power @ 0.5 m/s Straightness (over 15.5 inches travel) 9 Straightness Repeatability Hydraulic Oil Flow (m=76 cSt @ 90 F) Pumping Power required
9 10

Tension 75,000 2,500 2.7 1.8


1

Tension 29,750 3,000 4.7 0.8


5

Lateral 29,750 3,000 7.1 1.1

lb lb km lb/in lb/in m/s m/s2 lb in lb W in in gpm W

250,000 2,500 2,3 no limit 3.0 3 2.03,4 1.5 4 no limit no limit none infinite 4.2 3 9.4 3 20 4 84 0.2 3 100 3

Will cause permanent carriage deformation according to FEA analysis 2 Load which causes 50% closure of bearing gap 3 From fluid circuit mathematical model 4 Based on data from past non-modular hydrostatic bearings designed at MIT All analysis done by Nathan R. Kane at MIT

Will cause permanent deformation of rollers and races 6 Equal to theroetical dynamic load divided by load factor of 3 to account for the most demanding applications 7 Based on product catalogue data 8 Based on experimental data obtained by Nathan R. Kane at MIT

Defined as max. deviation of carriage relative to rail reference edges Quantity shown is typical for rolling element guides, according to S. Futami, A. Furutani, and S. Yoshida, Nanometer Positioning and its Microdynamics, Nanotechnology, Vol. 1, No. 1, 1990, pp.31-37

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1994 by Alexander H. Slocum

Technical advantages and tradeoffs associated with the HydroRailTM


HydroRailTM Feature
Very high "crash" resistance Potentially infinite bearing life High damping Zero static friction Low dynamic friction High Straightness Swarf particles can pass freely through bearing gap

Benefits for Various Applications


Greatly reduces the chance that a crash will result in expensive downtime for bearing repair. If fluid filter is replaced regularly, cost of rebuilding linear ways can be eliminated. Reduces problematic chatter, increases surface finish. Reduces servo reversal error; increases motion resolution, allowing 20 in infeeds or smaller. Reduces heat generation and hence reduces thermal errors at high speeds. Results in straighter surfaces, more accurate parts. Virtually immune to the extremely destructive effects of ceramic swarf when grinding ceramic materials. Allows bearing to remain accurate over several years of operation without a rebuild.

Estimated Carriage and Rail Costs Bearing Size 35 45 55 Per Carriage Per meter of rail
1 2

Fluid System Cost

6 5 To Power 4 Carriages of any $3,800 size $570 $600 $650 $700 To Power 8 Carriages of any $4,800 size $770 $800 $850 $900 To Power 12 Carriages of any $5,600 size

Estimates are based on an ultra precision rolling element linear guide system with similar manufacturing complexity Includes DC permanent magnet motor (1 hp per 4 carriages), power supply, gear pump, 3m high pressure filter, properly sized oil chiller with a 10 gallon tank, pressure relief value, a pressure measurement and control system, 10 foot hydraulic hose, and 15 gallons of hydraulic oil. Does not include fittings and hoses going to individual trucks, fluid gutters and drains, or a way protection system such as bellows.

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1994 by Alexander H. Slocum

New Possibilities for Machine Tool Manufacturers

Offer Check the Box Machine


Linear Bearing Option:

Hydrostatics to Customers Buying a N e w


HydroRailTM Hydrostatic Linear Guides

Standard Linear Guides

Upgrade an Entire Product Line Quickly and Inexpensively With minimal additions (such as adding drainage gutters for hydraulic oil), an old product line that uses standard linear guides can be rejuvenated by equipping the machines with HydroRailTM bearings. Introduce A New Ultra Performance Machine Tool Which is Very Cost Competitive Design a new ultra performance high speed machining center which takes full advantage of the performance capabilities of the HydroRailTM bearing. Promote the unique crash resistant, accuracy enhancing, and long bearing life features, and also the high value added to the machine tool by the HydroRailTM technology, which translates directly into a great value for the customer. Replace Costly Hand Scraped Way Systems In an effort to reduce assembly time and costs, countless machine tool manufacturers have spent thousands of R&D dollars trying to make rolling element guides work for them, only to give up and go back to using their old labor intensive, costly custom way systems (such as sliding and hydrodynamic systems which require hand scraping). For many of these companies, the HydroRailTM can offer the ultra high performance they require while also providing them with much of the savings that they are looking for.

New Possibilities for Machine Tool Users

Retrofit a Machine to Bring it to A New Level of Accuracy During a rebuild, a machine that uses standard linear guides can be economically upgraded to HydroRailTM bearings. For a modest investment, the machine can then can perform at a new level of accuracy.

Retrofit a Machine to Greatly Increase Bearing Life in Abrasive Environments When grinding ceramics or other hard materials, the abrasive swarf created always gets past even the best bearing seals, and then quickly wears the surfaces of rolling elements and races. Retrofitting such a machine with HydroRailTM bearings can eliminate this problem, since the bearing gap is large enough to allow swarf particles to pass through freely.

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1994 by Alexander H. Slocum

Porous Graphite Aerostatic bearings


Aerostatic bearings utilize a thin film of high pressure air (typically 690 kPa) to support a load:
Pa Po centered
Axial pressure profile

Po

Pa

Low clearance side

High clearance side

Since air has a very low viscosity, bearings gaps are small, on the order of 1-10 microns. Aerostatic bearings bearings can be configured in virtually all the ways hydrostatic bearings can. Because air bearings have essentially zero friction and are very clean running: They have extensive use in metrology equipment and in machines used in clean rooms.

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1994 by Alexander H. Slocum

Modular fluidstatic bearing systems can be easily made from off-the-shelf components:3 Porous graphite bearing pads (e.g., from Devitt Machinery in Aston PA). Ceramic Hydroguide pads from Wilbanks International. Hollow alumina beams (e.g., from Wilbanks International in Hillsboro OR). Hollow cast iron square tube (e.g., from Smith Tool Co. in Manasquan, NJ) Epoxy potting compound (with metal fillers to increase modulus) (e.g., DWH epoxy from Devitt Machinery).

Outer structure Potting epoxy Steel backing Porous graphite Moving member

Patent by Drew Devitt, Devitt Machinery, Aston, PA, "Method for Manufacturing Externally Pressurized Bearing Assemblies", #5,488,771, Feb. 6, 1996. 18-32

1994 by Alexander H. Slocum

Assembly procedure: The outside of the cast iron tube is finish ground. The modular porous graphite air bearing pads are held to the precision alumina beam by a vacuum. The beam is positioned with jigs with respect to the outside of the cast iron tube. The potting epoxy is injected between the pads and the cast iron.

After curing, when the air is off, the alumina beam is locked in place (self-braking). When air is applied, the cast iron tube expands a few m and the alumina beam floats.

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1994 by Alexander H. Slocum

Advanced Hydrostatic Bearings for High Speed Spindles


4

Since 1986, Prof. Slocum has been working on self compensated hydrostatic bearings. Dr. Kevin Wasson earned his Ph.D. working with Prof. Slocum on high speed hydrostatic bearings. Dr. Wasson has developed advanced designs and mathematical models, that allow him to deterministically design high speed surface self comepnsated hydrostatic bearings. These bearings can run on oil, water, or cryogenic fluids. These bearings have widespread application, from machine tool spindles, to rocket motors!

This section was prepared by Dr. Kevin Wasson, Principal Engineer, Aesop, Inc. PO Box 2126, Concord, NH 03302.

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1994 by Alexander H. Slocum

Conventional Hydrostatic Bearings

Compensation Resistance

Some type of external compensation resistances are required: Orifices. Capillaries. Servo Valves.

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1994 by Alexander H. Slocum

Advantages/Disadvantages of Hydrostatic Spindles


Compared to rolling element spindles, hydrostatic spindles have: Much lower static and dynamic run-out. Usually equal or better static stiffness at the tool-point. Much higher damping, higher dynamic stiffness. Higher tolerance to impact loads. No wear, potentially infinite life. Enables machining forces to be measured by measuring pocket pressures. Much higher power consumption, heat generation, temperature rise at high speeds (if oil is used). Typically higher cost, mostly due to the required support equipment.

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1994 by Alexander H. Slocum

Water Hydrostatic Machine Tool Spindles


Compared to oil, using water (or coolant) as the bearing lubricant results in: Much lower bearing power consumption (drag). Much lower temperature rise, thermal growth. Better ergonomics. No problems with cross-talk between oil and coolant systems. Requires tighter clearances to keep flow rates low. Can create clogging problems if issue is not addressed.

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1994 by Alexander H. Slocum

Self-Compensated Hydrostatic Bearings5


Conventional Self-Compensation

External Compensation Resistance

C L

C L

Eliminates clogging. Enables higher bearing stiffness. Eliminates the need to hand-tune inlet restrictors. Bearing load capacity is independent of the clearance. Enables the bearings to be located on the surface of the shaft; much more easy to manufacture.

U.S. Patents 5,281,032; 5,466,071; 5,533,814; other patents pending.

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1994 by Alexander H. Slocum

Prototype Test Spindle


Pulley-Drive Support Bearing Air Seal

Pulley-Drive Shaft

56 mm

Air Seal

Thrust Flange

Rear Bearing Front Bearing Rear Bearing Through-the-Tool Compensator Coolant Supply Channel

Front Bearing Compensator

Unique features: Self-compensated hydrostatic bearings. All bearing detail CNC-milled into the outer surface of the shaft with a ball end mill. Damping areas left in the centers of the bearing pockets. Unique thrust bearing provides preferential load capacity in the pushing direction. Air seals on front and rear of spindle prevent coolant leakage. Unique method to supply through-the-tool coolant.

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1994 by Alexander H. Slocum

Modeling Bearing Stiffness


La R3 R1 R3 La L1 La Ri La Ro L2 R3 R1 R3 R2 R2

h pad

R1a Supply Pump R2a R3a

R2b R1b

R3b

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1994 by Alexander H. Slocum

Modeling Static Spindle Stiffness

Finite Element Representation:


fc fb Fs

fa

Complications: Often many changes in cross-section. Shear deformations are not negligible for short spindles. Bearing characteristics are a strong function of the shaft bending.

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1994 by Alexander H. Slocum

Modeling the Effect of Pad Tilt


R1 R La L1 La Ri La Ro L2 h pad R5 R1 R4 R2 R3 4

La

R5

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1994 by Alexander H. Slocum

Predicted and Measured Spindle Stiffness


Fs f b f c

fa

Front Bearing

Rear Bearing

Pulley Bearing

Predicted Stiffness: 131,700 lbf/in Measured Stiffness: 130,500 lbf/in

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1994 by Alexander H. Slocum

Measured Dynamic Spindle Stiffness

Pump Noise

Resonance

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1994 by Alexander H. Slocum

Measured Spindle Radial Error Motion

Speed (rpm) 1,000 2,000 5,000 7,000 10,000

Total Runout (in) 29.0 31.2 36.2 76.5 67.0

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1994 by Alexander H. Slocum

Modeling Viscous Friction


La y ha hp Lp Shaft Rotation

Flow on the lands typically remains laminar up to speeds of 2 million DN. Flow in the pockets typically becomes turbulent at speeds greater than 0.1 million DN.
Experimental Data for Pocket Depth of: 2.06 mm 1.04 mm 0.53 mm

Turbulent Analytical Solution

T V D2 Laminar Analytical Solution

Re

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1994 by Alexander H. Slocum

New Method to Reduce Bearing Friction and Increase Bearing Damping


Theoretical
Grooves Machined with a Ball-Nose End Mill

Manufactured

bm

bm

bm Bearing Pocket

DampingEnhancing and FrictionReducing Land Area

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1994 by Alexander H. Slocum

Relative Pocket and Land Friction

0.005 Nm/s

0.0013 Nm/s

0.0008 Nm/s

Calculated for a clearance of 20 m, pocket depth of 2 mm, bearing diameter of 90 mm.

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1994 by Alexander H. Slocum

Power Consumption of Prototype Spindle

Temperature Rise

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