Selection criteria for ball screws The following factors should be considered when selecting the ball screw

for a given application: Degree of accuracy required e (lead deviation) It is the difference between the actual mean travel and the nominal or specified travel. Ball screw classified to tow types according to accuracy 1-Positioning ball screw type (p) Ball screw used for precision positioning which enables to indirect measurement of axial travel from the angle of rotation and the lead, without backlash (preloaded). Backlash is total free axial displacement between the nut and the ball screw shaft when there is no rotation between the components 2-Transport ball screw type (T) Ball screw the travel of which is measured by a separate measuring system independent of angle of rotation and lead of the ball screw.

Permissible deviations

The ball screws accuracy tested in six standard tolerance grades (table .) in conformance with International Tolerance grade numbers (IT) (ISO 286-2:1988). Standard tolerance grade 0 Standard tolerance grade 1 Standard tolerance grade 3 Standard tolerance grade 5 Standard tolerance grade 7 Standard tolerance grade 10 Increasing requirements on accuracy and function

Table standard tolerance grade Tolerances Tolerances on specified travel ( ep) for the useful travel (lu) taken directly from ISO 286-2 1988, table 1. Value of ( ep ) for useful travel (lu) of greater than or equal to 3150 mm were calculated be linear extrapolation . Tolerances on travel variation, vup, in micrometers, within useful travel lu were evaluated using the following equations:

- Grade 0: vup = 0,0035 * lu + 2,4

- Grade 1: vup = 0,0045 * lu + 4,6 - Grade 3: vup = 0,009 * lu + 9,2 - Grade 5: vup = 0,018 * lu + 18,4 Where lu is the geometrical mean, in millimeters, of the extreme lengths of each step of measured travel given in Table (): lu = (lumax*lumin)1/2

In service load condation

Basic static load rating Co The static load rating is an axial, concentrically acting force that induce s a permanent deformation of 0.0001 x the ball diameter between the ball and the ball raceway. Basic dynamic load rating C The dynamic load rating is an axial concentrically acting force of constant magnitude and direction under which 90 % of a sufficiently large amount of identical ball screws can achieve a nominal service life of one million revolutions. Service life The nominal life is expressed by the number of revolutions (number of operating hours at constant speed) that will be attained or exceeded by 90 % of a representative sample of identical ball screws before the first signs of material fatigue become evident. The nominal life is designated as L or Lh depending on whether it is specified in revolutions or hours. Critical speed

Rotation speed of the ball screw nut or ball screw shaft that produces resonant vibrations of the ball screw Buckling load Maximum compressive axial load that can be applied to the ball screw without resulting in its permanent structural deformation.

Rigidity of ball screws Measure of the resistance of a ball screw to deformation (load per unit of deformation ). Rigidity is function of the components of the ball screw and the preload applied. Calculation formulas Average speed and Average load Average speed where the speed fluctuate

Nav = average speed (rpm) , n = angular speed of ball screw shaft (rpm) , t = discrete time ( %) Where load fluctuate and the speed is constant

 Where both the load and the speed fluctuate

Service life in revolutions [ ]

L = service life (revolutions) Fm = average load (N) C = dynamic load (N) Service life in hours

Lh = service life (h) L = service life (revolutions) nav = average speed (rpm) Drive torque and drive power Drive torque for conversion of rotary motion into linear motion:-

Transmitted torque motion

for conversion of linear motion into rotary

Mta = drive torque (Nm)

Mte = transmitted torque (Nm) F = operating load (N) P = lead (mm) = mechanical efficiency (approx. 0.9) = mechanical efficiency (approx. 0.8) Drive power Pa

Pa = drive power (kW) Mta = drive torque (Nm) n = speed (rpm)

selection ball screw for z axis : Step 1:- positioning accuracy Selection according to international standard of accuracy grade for ball screw, selected grade 3 (table ) Step 2:- ball screw lead Lead screw = Rapid feed rate (Vmax) / Max speed of motor (N max) Assumed rapid feed rate 5000 mm/min

Max speed of motor 1000 rpm Lead screw 5000/ 1000 = 5 mm Lead screw = 5 mm Step 3 : Total length = thread length+ journal end length Thread length = stroke + nut length + unused thread The total length of z axis is 400mm Step 4 :- Load condition According to plasma cutting procedure there is no fluctuating load like lathes machines and milling machines the load just the weight of the axis components, if the load is fluctuating , used equation no... to calculate the mean load. Assume the load of the axis component is 20kg or (200 N) Speed condition

Assume

Step 5 :- Preload calculating In this design used nut without preload

Step 6

Calculating basic dynamic load Design for 30000 hours of working

[ [ * Step 7 :- Screw diameter Selected screw diameter depended on -basic dynamic load (2258.5 N) -ball screw lead (5 mm) -critical speed

] ] +

Critical speed depends on the of the screw diameter, the type of the end fixing and the free length. As general critical speed of shaft Where: g = gravity acceleration (9.81 m/s2) st = total maximum static deflection Critical speed can calculate from formulas which supplies from the ball screw companies.

HIWIN Company formula

= critical speed of ball screw shaft (rpm) . = permissible speed of ball screw shaft (rpm). = Root diameter of screw shaft ( mm). = distance between support bearing (mm). =factor of different mounting type . Fixed fixed Fixed -supported Supported supported Fixed - free For Rexroth Company

The different in the factor of different mounting type Fixed fixed Fixed -supported Supported supported

Fixed - free For this design assumed Screw diameter = 12mm Lead Length = 5 mm = 400 mm

Fixed - supported HIWIN Company formula

For Rexroth Company

Buckling load:As general buckling

where F = maximum or critical force (vertical load on column), E = modulus of elasticity,

I = area moment of inertia, l = unsupported length of column, K = column effective length factor, whose value depends on the conditions of end support of the column, as follows. Supported Supported K = 1.0. Fixed Fixed K = 0.50. Fixed Supported K = 1.0/2.0. Fixed Free K = 2.0. The ball screws companies manufacturing ball screws from different material so that supplied the formula and charts of the buckling for the customers . HIWIN Company ( )

permissible load (

) ) .

maximum permissible load ( = factor of different mounting type Fixed fixed

fixed Supported Supported supported Fixed free

Rexroth Company ( )

Supported Supported Fixed Fixed Fixed Supported Fixed Free = 2.6. = 40.6.

= 10.2.

= 20.4.

in the both selection (HIWIN & Rexroth) the load(200 N) is less than buckling load.

Step 8:- Drive torque

For this axis :-

Drive Power:-

Take factor of safety = 2 Total motor power = From the HIWIN Ball screws technical information catalog, selected FSI nut type. The ball screw specified: - 1R16-5T3-FSI-400-500-0.012

Selection ball screw for X axis Step 1 : positioning accuracy

Selection according to international standard of accuracy grade for ball screw, selected grade 3 (table ) Step 2 : ball screw lead Lead screw = Rapid feed rate (Vmax) / Max speed of motor (N max) Assumed rapid feed rate 10000 mm/min Max speed of motor 1000 rpm Lead screw 10000/ 1000 = 10 mm Lead screw = 10 mm Step 3 : Total length = thread length+ journal end length Thread length = stroke + nut length + unused thread The total length of z axis is 1500mm Step 4:- Load condition Assume the load of the axis component is 40kg or (400 N) Speed condition

Assume

Step 5 :- Preload calculating

Step 6 :- Calculating basic dynamic load Design for 30000 hours of working

[ [ *

] ] +

Step 7 :- Screw diameter For this design assumed Screw diameter = 32mm Lead = 10 mm

Length

= 1500 mm

Fixed - supported HIWIN Company formula

For Rexroth Company

Buckling load:HIWIN Company ( )

Rexroth Company ( )

Step 8:- Drive torque

For this axis :-

Drive Power:-

Take factor of safety = 2 Total motor power = From the HIWIN Ball screws technical information catalog, selected FSI nut type. The ball screw specified: - 1R32-5T3-FSI-1500-1600-0.012

Selection ball screw for y axis Step 1 : positioning accuracy Selection according to international standard of accuracy grade for ball screw, selected grade 3 (table ) Step 2 : ball screw lead Lead screw = Rapid feed rate (Vmax) / Max speed of motor (N max) Assumed rapid feed rate 10000 mm/min Max speed of motor 1000 rpm Lead screw 10000/ 1000 = 10 mm Lead screw = 10 mm Step 3 : Total length = thread length+ journal end length Thread length = stroke + nut length + unused thread The total length of z axis is 2500mm Step 4:- Load condition Assume the load of the axis component is 55kg or (550 N) Speed condition

Assume

Step 5 :- Preload calculating

Step 6 :- Calculating basic dynamic load Design for 30000 hours of working

[ [ *

] ] +

Step 7 :- Screw diameter For this design assumed Screw diameter = 32mm Lead Length Fixed fixed = 10 mm = 2500 mm

HIWIN Company formula

For Rexroth Company

Buckling load:HIWIN Company

Rexroth Company

Step 8:- Drive torque

For this axis :-

Drive Power:-

Take factor of safety = 2 Total motor power =