Dynomax Spindle Blog

Knowing how much power is required to perform a machining operation is useful when planning new machining operations, or for optimizing existing machining operations.  It is also vital information to have when properly selecting a spindle.  The available power on any machine tool spindle limits the size of the cut it can take.  When large amounts of metal must be removed from a work piece, it is advisable to estimate the cutting conditions that will utilize the maximum power from the machine.  Some machining operations will require only light cuts for which the machine obviously has enough power; in these cases estimating the power required may not as necessary for success.

Whenever possible the maximum power available on a machine tool should be use when heavy cuts must be taken.  The cutting conditions for utilizing the maximum power should be selected in the following order:

1) Select the maximum depth of cut that can be used;

2) Select the maximum feed rate that can be used;

3) Estimate the cutting speed that will utilize the maximum power available on the machine.

This sequence is based on obtaining the longest tool life of the cutting tool and at the same time obtaining as much production as possible from the machine.  The life of a cutting tool is most affected by the cutting speed then by the feed rate, and least of all by the depth of cut. The maximum metal removal rate that a given machine is capable of machining from a given material is used as the basis for estimating the cutting speed that will utilize all the power available on the machine.

In the opinion of any spindle designer, the ultimate spindle would have the following characteristics:

1. Unlimited Speed

2. High Power

3. Long Life

4. Self-Balancing

5. Self-Diagnostic

As unattainable as these qualities may sound, they will be fulfilled in future spindle designs.  Advances in bearing technology such as magnetic and fluid bearings will permit previously unattainably high speeds as these non-contact bearing systems will exhibit no mechanical wear, a leading cause of existing bearing failure.  Superconducting materials and new motor technologies are being developed to provide higher power in more compact packages with less heat.  Electronic sensors are coming online that will monitor all aspects of a spindles operation, including cutting loads.  Any imbalance can instantly be compensated for as the spindle is running and diagnostic information can be relayed to the CNC control for protective action.

When new technology becomes available, you can count on Dynomax to be on the cutting edge.  Since we design our spindles inhouse, we are constantly looking for new and innovative ways to improve our product using the latest engineering and technical knowledge.  Check back often to see what’s new in the spindle industry.