Fluids play a major role for production machinery and serve for very different tasks as lubricating, tempering, cleaning, transmitting force and energy. Due to maintenance requirements and the environmental impact their utilization is under discussion and alternatives are looked for. In this paper an overview of the latest research activities in the field of fluidic elements on machine tools is presented. The topic of the paper includes an overview of the fluids used in machine tools, the usage of fluidic elements, supply and treatment units, and their influence on machine tools performance. A link to fluidic media on energy efficiency is given. Research challenges in order to increase the performance of machine tools are discussed. The paper excludes metal working fluids, which have been treated in Brinksmeier et al. [33].

Fluid elements in machine tools

We proposed a method to predict the heights of upper and lower air-oil interfaces of the non-operating and operating fluid dynamic bearings (FDBs) in the tied shaft of hard disk drives. To predict the height of upper and lower air-oil interfaces, we formulated the linear pressure and volume equations in both cases of non-operating and operating conditions, respectively. The initial heights of upper and lower air-oil interfaces are determined by pressure and volume equations during non-operating condition. Pressure equation consists of capillary pressure, atmospheric pressure, hydrostatic pressure and applied pressure, and volume equation consists of the volumes of the clearance and the injected oil. In case of operating condition, hydrodynamic pressure generated by grooved bearings is additionally considered in the pressure equation, because heights of air-oil interfaces vary due to hydrodynamic pressure during operating condition. The linear pressure and volume equations were solved simultaneously to calculate the heights of upper and lower air-oil interfaces both in non-operating and operating conditions. In case of non-operating conditions, the height of upper air-oil interface increases with the increase of pressure difference because pressure of lower air-oil interface is higher than that of upper air-oil interface. Since the volume of injected oil is constant, height of lower air-oil interface decreases due to pressure difference. In case of operating conditions, the height of upper air-oil interface decreases according to rotating speed because more oil flows inside the FDBs and recirculation channel than upper seal. On the other hand, the height of the lower air-oil interface increases because volume variation of the oil due to the increase of the flying height is smaller than that due to the decrease of the height of the upper air-oil interface. Finally, we verified the proposed method by measuring the height of upper air-oil interface both in the non-operating and operating conditions.

Height analysis of the air-oil interfaces in the non-operating and operating FDBs in a tied shaft of HDDs

The fundamental characteristics of the taper seal used to prevent oil leakage from fluid bearings were analysed theoretically and investigated experimentally. The three-dimensional flow field was theoretically analysed using numerical fluid dynamics, and the profile of the oil meniscus was calculated using the balance between the pressure field and surface tension. The oil meniscus was experimentally investigated using a micro-focus laser microscope. Three triggers for oil leakage were identified: the oil contact angle on the sleeve surface becoming excessive, the convex portion of the meniscus profile extending beyond the edge of the sleeve, and cavitation occurring in the oil.

Analysis and experimental study on oil leakage from fluid bearing

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Analysis and experimental study on oil leakage from fluid bearing