A Physics-Based Model-Data-Driven Method for Spindle Health Diagnosis, Part II: Dynamic Simulation and Validation

Mathematical modeling of bearing faults, worn tool holder taper contact interface, and unbalance are presented and integrated into a digital dynamic model of spindles in Part I of this paper. These faults lead to changes in preload and dynamic stiffness over time, consequently resulting in observable vibrations. This paper predicts the vibrations of a spindle at a particular measurement location by simulating the presence of a specific fault or multiple faults during spindle rotation. The vibration spectra generated by the digital spindle model at the spindle speed and its harmonics, the changes in the natural frequencies, and dynamic stiffnesses are correlated to faults with experimental validations. The simulated vibration spectrums are later used in training an artificial neural network for fault condition monitoring presented in Part III of the paper.