Over the past decade, the rapid advancement of high-speed processing technology has led to a surge in demand for high-speed CNC machine tools across various industries. Particularly in aerospace, automotive, mold manufacturing, and motorcycle sectors, these machines have become essential. Countries like the United States, Japan, Germany, Italy, and Switzerland have developed a range of commercial high-speed machining centers. The following table highlights some of the top brands that have emerged in the global machine tool market.
**New High-Speed Machining Center Manufacturers**
| Manufacturer | Country | Machine Name & Model | Spindle Max Speed (r/min) | Max Feed Rate (m/min) | Spindle Drive Power (kW) |
|--------------|---------|----------------------|----------------------------|------------------------|---------------------------|
| Cincinnati Milacron | USA | Maxim 500 Horizontal Machining Center | 20,000 | 28 | 12 |
| Ingersoll | USA | HVM800 High-speed Horizontal Machining Center | 20,000 | 76.2 | 45 |
| Mikron | USA | HSM700 High-speed Vertical Machining Center | 42,000 | 40 | 14 |
| Ex-cell-O | Germany | XHC241 High-speed Horizontal Machining Center | 24,000 | 120 | 40 |
| RODERS | Germany | RFM1000 Machining Center | 42,000 | 30 | 20–30 |
| Makino | Japan | A55-A128 Machining Center | 40,000 | 50 | 22 |
| Niigata Ironworks | Japan | VZ40 Machining Center | 50,000 | 20 | 18.5 |
| Mazak | Japan | Super-400H Machining Center | 25,000 | 15 | 18.5 |
The figures below illustrate the torque-power characteristics of high-speed spindles with and without vector control:
**(a) No Vector Control**

**(b) With Vector Control**

Figure 1: Torque-Power Characteristics
High-speed machine tools are typically CNC and precision machines, with the most important feature being the realization of "zero drive." This involves eliminating all mechanical transmission components such as belts, gears, and clutches between the motor and the spindle, resulting in an integrated system. This design offers advantages such as minimal inertia, fast response, and the ability to achieve extremely high speeds, quick acceleration, and precise positioning.
AC variable frequency speed control and vector control technologies provide a wide speed range and ideal torque-power characteristics. This allows for both roughing and high-speed finishing in a single setup. The modular design of the spindle components enables standardized production, making it easier for manufacturers to customize high-speed machine tools according to user needs.
Despite the simplified mechanical structure, the manufacturing process is highly demanding. Issues such as heat dissipation, high-speed balancing, and bearing lubrication must be carefully addressed to ensure stable and reliable operation. This paper explores the challenges in designing and manufacturing high-speed, high-power spindles for milling and boring applications, drawing on research conducted at our institution.
### 1. Basic Parameters and Structure of Motor Spindle
Key parameters include maximum spindle speed, constant power speed range, rated power, maximum torque, front journal diameter, and bearing span. These parameters are determined based on user requirements and typical part analysis. Two types of high-speed machine tools are usually designed: high-speed and high-rigidity models. The former is used for light alloys and composites, while the latter is suitable for difficult-to-machine materials like high-strength steel and heat-resistant alloys.
Electric spindles are typically installed on high-speed machining centers. When designing them, it's crucial to select a motor and control module with excellent torque-power characteristics and a broad speed range. There are two layout methods for high-speed motor spindles, depending on the relative position of the motor and the bearings.
### 2. Main Heat Sources and Solutions
Heat generation in electric spindles is a major concern. The main sources are the motor and the bearings. To address this, cooling systems such as oil-water heat exchange and oil-air lubrication are employed. The GD-2 electric spindle, for example, uses an external oil circulation system with a spiral groove cooling jacket around the stator to efficiently remove heat from the motor.
Additionally, ceramic ball bearings are commonly used due to their low density, high hardness, and excellent thermal properties. These bearings allow for high-speed operation with minimal temperature rise and long service life. An oil-air lubrication system further enhances cooling efficiency, especially at high dm·n values.
### 3. Dynamic Balance Design
Electric spindles often operate at speeds exceeding 10,000 rpm, with some reaching up to 100,000 rpm. Even small imbalances can cause significant vibration, affecting machining accuracy. Therefore, strict dynamic balancing is required. Components are precisely machined and assembled to achieve a balance level of 0.4 or higher. Special attention is given to interference fits and symmetrical designs to ensure stability during operation.
### 4. Conclusion
As a critical component of high-speed CNC machines, the performance of the spindle directly impacts the efficiency and precision of the entire system. Countries worldwide are investing heavily in the development of high-speed spindles, establishing professional production bases with advanced facilities and controlled environments. While China is still in the early stages of mass production, there is significant potential for growth. Continued research and technological development are essential to bridge the gap with international standards and promote the widespread adoption of high-speed machining in China.
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