User: Levicron GmbH
Contact: Dr. Ralf Dupont
Date: June 2024
Crash and overload protection with new aerostatic hybrid bearing technology (also available as upgrade)
Machine manufacturers and operators know the problem: A collision of the tool or incorrect programming often leads to spindle damages that requires repair or even replacement. These problems cost you time and money. With our newly developed aerostatic hybrid bearing, this is now changing. In the event of an overload or collision, there is direct contact between the shaft and bearing, but thanks to the new material pairing, there is no jamming of the shaft or damage to the spindle.
In intensive tests, we deliberately overloaded the bearing and the motor within the same spindle, causing tool breakage due to overloading and provoking collisions with the workpiece.
The result: the spindle bearing was not damaged. We only had to replace the tool and could continue working with the same spindle without any problems.
Watch video
(First test)
⌀ 5 mm tool
Watch video
(Second test)
⌀ 6 mm tool
Information and results
Application:
Deliberate tool overload and collision with workpiece (steel, 1.4057, HRC 43)
Machine:
Hardinge Bridgeport GX1000 (3 axes)
Used Machining spindle:
ASD060H25 at up to 60,000 rpm
Trials table
| Test results, contour milling *) | Test Resuts for finding motor power/current limit **) | |
| Material | 1.4057, HRC43 | 1.4057, HRC43 |
| Face milling cutter | Diameter ⌀ 5 mm, 4 Cutting | Diameter ⌀ 4 mm, 4 Cutting |
| Speed | 32,000 rpm (equals 500 m/min) ***) | 11,000 rpm (equals 140 m/min) |
| Cutting depth (ap) | 5 mm | 5 mm |
| Radial cutting depth (ae) | 0.3 mm | 0.3 mm |
| Feed rate (f) | 10 m/min | 10 m/min |
| *) Overload, without machine error; **) 10A nominal, 19 A peak, I²t 5 seconds; ***) 200% above the recommended cutting speed |
Making our spindle solutions more insensitive to overload and crash
The Hybrid-Bearing technology is currently available for new spindles and as an upgrade for our
xASD-Cx,
xASD-H25/A and
xASD-H32/A. In both cases there is no change in size, design or operation compared to spindle with our well-proven standard beargins. Apart from a significantly increased overload and crash safety, nothing changes for you.
