Design and optimisation of advanced bearing system for ultra-precision plastic electronics production systems

Abstract

Purpose The paper aims to use aluminium alloy to substitute steel as the main material of ultra-precision hydro-static bearing system for an ultra-precision plastic electronics production system to lower the manufacturing cost. The total cost of diamond turning and nickel-based electroless coating of an aluminium alloy bearing is expected to be less than the cost of manufacturing a stainless steel bearing. Design/methodology/approach The paper used a large amount of theoretical calculation to obtain optimal specifications of the bearing system. ANSYS modelling was selected to simulate the deflection of the bearing shaft under high oil pressure. Hundreds of measurements were conducted after the bearing had been manufactured. Findings The paper provides industrial application insights on using aluminium alloy with a high-quality nickle-based electroless coating as a successful substitution of stainless steel. This created a more economic hydro-static bearing system. Research limitations/implications Because of the time limit, different rotational speed tests shall be conducted in the future. Practical implications The paper provides implications for the application of nickel-based electroless coating to improve the surface property and bending strength of aluminium alloy, as well as classifying ultra-precision diamond turning as an economic finishing process. Originality/value This paper has identified the importance of aluminium alloy with a nickel-based electroless coating as the substitution of stainless steel in a precision hydro-static bearing system.