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In order to analyze the bearing wear in the spindle system considering different speed and load conditions, a four-bearing spindle system was investigated. Two different working conditions, Case I and Case II, are considered. Case I condition has lower spindle speed and higher external loads and preload than Case II condition. Based on Archard model, a new wear depth model of angular contact ball bearing is presented which takes into account the influence of lubrication on bearing wear. The wear depths of inner and outer raceways for angular contact ball bearings are calculated based on the motion parameters and contact parameters of ball elements which are obtained by spindle system model. The effects of spindle speed, angular misalignment, external load and surface roughness on the wear depths of bearings are comparatively studied. Increasing spindle speed at Case I condition can significantly increase bearing wear. Angular misalignment may be beneficial to individual bearing, but overall, no angular misalignment is the most beneficial to spindle system. The change rate of wear depth of bearing raceway with external loads at Case I condition is much greater than that at Case II condition. The surface roughness can significantly affect the bearing wear in the spindle system, especially at Case I condition.

Comparative study of bearing wear in spindle system at different working conditions