Design and Machining of a Spherical Shell Rotor for a Magnetically Levitated Momentum Ball

Abstract

Ball-shell rotors with non-standard shapes, non-uniform conductive coatings, and eccentric masses machined by conventional processes constrain the improvement of levitation and torque accuracy of magnetically levitated momentum balls. This paper focuses on the machining method of multilayer ball-shell rotors to develop a ball-shell rotor with a standard shape and uniform conductive coating, which can improve the levitation and torque accuracy of magnetically levitated momentum balls. In this paper, a machining method for multi-coated ball-shell rotors is proposed. The machining process combining hemispherical surface and workpiece is adopted, and the whole sphere is assembled by threading, which effectively reduces the machining error. The influence of the cutting depth and feed rate of the tool on the cutting force of the ball shell was analyzed through the cutting force model. The effect of cutting force on the deformation of the ball shell was analyzed by the finite element method. The superiority of the machining method was verified by measuring the dimensions of the ball shell with a coordinate measuring machine. Compared with the traditional machining process and assembly method, the proposed ball-shell rotor machining method effectively improves the dimensional accuracy, reduces the center of mass to center of mass deviation, and ensures the levitation accuracy and output torque accuracy of the magnetically levitated momentum ball. Measurement results show that the diameter values of the pure iron ball shell are between 98.694 and 98.707 mm with a machining error of ±0.007 mm, and the diameter values of the spray-painted ball shell are between 99.490 and 99.510 mm with a machining error of ±0.01 mm. The machining static equilibrium of the pure iron ball shell and the spray-painted ball shell is good by the static equilibrium test method.